Surgical instrument with primary and safety processors

ABSTRACT

A surgical instrument includes a motor operably coupled to a firing member, wherein the motor is configured to generate at least one rotational motion to motivate the firing member to cause staples to be deployed during a firing stroke. The surgical instrument includes a primary processor configured to determine a first acceleration of the firing member during the firing stroke, and compare the first acceleration to predetermined threshold acceleration. The surgical instrument also includes a secondary processor configured to determine a second acceleration of the firing member during the firing stroke, and compare the second acceleration to the predetermined threshold value.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a side elevational view of a surgical system comprising ahandle assembly and multiple interchangeable surgical tool assembliesthat may be used therewith;

FIG. 2 is a perspective view of one of the interchangeable surgical toolassemblies of FIG. 1 operably coupled to the handle assembly of FIG. 1;

FIG. 3 is an exploded assembly view of portions of the handle assemblyand interchangeable surgical tool assembly of FIGS. 1 and 2;

FIG. 4 is a perspective view of another one of the interchangeablesurgical tool assemblies depicted in FIG. 1;

FIG. 5 is a partial cross-sectional perspective view of theinterchangeable surgical tool assembly of FIG. 4;

FIG. 6 is another partial cross-sectional view of a portion of theinterchangeable surgical tool assembly of FIGS. 4 and 5;

FIG. 7 is an exploded assembly view of a portion of the interchangeablesurgical tool assembly of FIGS. 4-6;

FIG. 7A is an enlarged top view of a portion of an elastic spineassembly of the interchangeable surgical tool assembly of FIG. 7;

FIG. 8 is another exploded assembly view of a portion of theinterchangeable surgical tool assembly of FIGS. 4-7;

FIG. 9 is another cross-sectional perspective view of a surgical endeffector portion of the interchangeable surgical tool assembly of FIGS.4-8;

FIG. 10 is an exploded assembly view of the surgical end effectorportion of the interchangeable surgical tool assembly depicted in FIG.9;

FIG. 11 is a perspective view, a side elevational view and a frontelevational view of a firing member embodiment that may be employed inthe interchangeable surgical tool assembly of FIG. 10;

FIG. 12 is a perspective view of an anvil that may be employed in theinterchangeable surgical tool assembly of FIG. 4;

FIG. 13 is a cross-sectional side elevational view of the anvil of FIG.12;

FIG. 14 is a bottom view of the anvil of FIGS. 12 and 13;

FIG. 15 is a cross-sectional side elevational view of a portion of asurgical end effector and shaft portion of the interchangeable surgicaltool assembly of FIG. 4 with an unspent or unfired surgical staplecartridge properly seated with an elongate channel of the surgical endeffector;

FIG. 16 is another cross-sectional side elevational view of the surgicalend effector and shaft portion of FIG. 15 after the surgical staplecartridge has been at least partially fired and a firing member thereofis being retracted to a starting position;

FIG. 17 is another cross-sectional side elevational view of the surgicalend effector and shaft portion of FIG. 16 after the firing member hasbeen fully retracted back to the starting position;

FIG. 18 is a top cross-sectional view of the surgical end effector andshaft portion depicted in FIG. 15 with the unspent or unfired surgicalstaple cartridge properly seated with the elongate channel of thesurgical end effector;

FIG. 19 is another top cross-sectional view of the surgical end effectorof FIG. 18 with a surgical staple cartridge mounted therein that hasbeen at least partially fired and illustrates the firing member retainedin a locked position;

FIG. 20 is a partial cross-sectional view of portions of the anvil andelongate channel of the interchangeable tool assembly of FIG. 4;

FIG. 21 is an exploded side elevational view of portions of the anviland elongate channel of FIG. 20;

FIG. 22 is a rear perspective view of an anvil mounting portion of ananvil embodiment;

FIG. 23 is a rear perspective view of an anvil mounting portion ofanother anvil embodiment;

FIG. 24 is a rear perspective view of an anvil mounting portion ofanother anvil embodiment;

FIG. 25 is a perspective view of an anvil embodiment;

FIG. 26 is an exploded perspective view of the anvil of FIG. 25;

FIG. 27 is a cross-sectional end view of the anvil of FIG. 25;

FIG. 28 is a perspective view of another anvil embodiment;

FIG. 29 is an exploded perspective view of the anvil embodiment of FIG.28;

FIG. 30 is a top view of a distal end portion of an anvil body portionof the anvil of FIG. 28;

FIG. 31 is a top view of a distal end portion of an anvil body portionof another anvil embodiment;

FIG. 32 is a cross-sectional end perspective view of the anvil of FIG.31;

FIG. 33 is a cross-sectional end perspective view of another anvilembodiment;

FIG. 34 is a perspective view of a closure member embodiment comprisinga distal closure tube segment;

FIG. 35 is a cross-sectional side elevational view of the closure memberembodiment of FIG. 34;

FIG. 36 is a partial cross-sectional view of an interchangeable surgicaltool assembly embodiment showing a position of an anvil mounting portionof an anvil in a fully closed position and a firing member thereof in astarting position;

FIG. 37 is another partial cross-sectional view of the interchangeablesurgical tool assembly of FIG. 36 at the commencement of an openingprocess;

FIG. 38 is another partial cross-sectional view of the interchangeablesurgical tool assembly of FIG. 37 with the anvil in the fully openedposition;

FIG. 39 is a side elevational view of a portion of the interchangeablesurgical tool assembly of FIG. 36;

FIG. 40 is a side elevational view of a portion of the interchangeablesurgical tool assembly of FIG. 37;

FIG. 41 is a side elevational view of a portion of the interchangeablesurgical tool assembly of FIG. 38;

FIG. 42 is a cross-sectional side elevational view of another closuremember embodiment;

FIG. 43 is a cross-sectional end view of the closure member of FIG. 42;

FIG. 44 is a cross-sectional end view of another closure memberembodiment;

FIG. 45 is a cross-sectional end view of another closure memberembodiment;

FIG. 46 is a cross-sectional end view of another closure memberembodiment;

FIG. 47 is a partial cross-sectional view of portions of a surgical endeffector of an interchangeable tool assembly illustrated in FIG. 1;

FIG. 48 is a partial cross-sectional view of portions of a surgical endeffector of the interchangeable surgical tool assembly of FIG. 5;

FIG. 49 is another cross-sectional view of the surgical end effector ofFIG. 48;

FIG. 50 is a partial perspective view of a portion of an underside of ananvil embodiment;

FIG. 51 is a partial cross-sectional view of a portion of theinterchangeable surgical tool assembly of FIG. 5 with an anvil of asurgical end effector thereof in a fully opened position;

FIG. 52 is another partial cross-sectional view of a portion of theinterchangeable surgical tool assembly of FIG. 51 with the anvil of thesurgical end effector thereof in a first closed position;

FIG. 53 is another partial cross-sectional view of a portion of theinterchangeable surgical tool assembly of FIG. 51 at the commencement ofthe firing process wherein the anvil is in the first closed position anda firing member of the surgical end effector thereof has moved distallyout of a starting position;

FIG. 54 is another partial cross-sectional view of a portion of theinterchangeable surgical tool assembly of FIG. 51 wherein the anvil isin a second closed position and the firing member has been distallyadvanced into a surgical staple cartridge of the surgical end effectorthereof;

FIG. 55 is a graphical comparison of firing energy versus time fordifferent interchangeable surgical tool assemblies;

FIG. 56 is a graphical depiction of force to fire improvements andcomparisons of firing loads verses the percentage of firing distancethat the firing member thereof has traveled for four differentinterchangeable surgical tool assemblies;

FIG. 57 is a perspective view of an end effector of a surgical staplinginstrument including a staple cartridge in accordance with at least oneembodiment;

FIG. 58 is an exploded view of the end effector of FIG. 57;

FIG. 59 is a perspective view of the staple cartridge FIG. 57;

FIG. 60 is a partial perspective view of a channel of the end effectorof FIG. 57 configured to receive the staple cartridge of FIG. 57;

FIG. 60A is a partial perspective view of the channel of FIG. 60;

FIG. 60B is a circuit diagram of a cartridge circuit of the staplecartridge of FIG. 59;

FIG. 60C is a circuit diagram of a carrier circuit of the end effectorof FIG. 57;

FIG. 61 is a bottom partial view of the end effector of FIG. 57illustrating an intact trace element and a sled in a starting positionin accordance with at least one embodiment;

FIG. 62 is a bottom partial view of the end effector of FIG. 57illustrating a broken trace element and a sled in a partially advancedposition in accordance with at least one embodiment;

FIG. 62A is a block diagram illustrating an electrical circuit inaccordance with at least one embodiment;

FIG. 62B is a block diagram illustrating an electrical circuit inaccordance with at least one embodiment;

FIG. 62C is a block diagram illustrating an electrical circuit inaccordance with at least one embodiment;

FIG. 62D is a block diagram illustrating an electrical circuit inaccordance with at least one embodiment;

FIG. 63 is a circuit diagram of a safety mechanism of the end effectorof FIG. 57 in accordance with at least one embodiment;

FIG. 64 is a switch of the circuit diagram of FIG. 63 in an openconfiguration in accordance with at least one embodiment;

FIG. 65 illustrates the switch of FIG. 64 in a closed configuration;

FIG. 65A is a safety mechanism of the end effector of FIG. 57 inaccordance with at least one embodiment;

FIG. 65B is a logic diagram of a method for controlling the firing of asurgical stapling and cutting instrument in accordance with at least oneembodiment;

FIG. 66 is a partial perspective view of a staple cartridge including aconductive gate in accordance with at least one embodiment;

FIG. 67 is a partial exploded view of the staple cartridge of FIG. 66;

FIG. 68 is a cross-sectional view of the staple cartridge of FIG. 67showing the conductive gate in a fully closed configuration;

FIG. 69 is a cross-sectional view of the staple cartridge of FIG. 67showing the conductive gate in an open configuration;

FIG. 70 is a cross-sectional view of the staple cartridge of FIG. 67showing the conductive gate transitioning from an open configuration toa partially closed configuration;

FIG. 71 is a block diagram illustrating an electrical circuit configuredto activate/deactivate a firing system of a surgical stapling andcutting instrument in accordance with at least one embodiment;

FIG. 72 illustrates a controller a surgical stapling and cuttinginstrument in accordance with at least one embodiment;

FIG. 73 illustrates a combinational logic circuit of a surgical staplingand cutting instrument in accordance with at least one embodiment;

FIG. 74 illustrates a sequential logic circuit of a surgical staplingand cutting instrument in accordance with at least one embodiment;

FIG. 75 is an electromagnetic lockout mechanism for a surgical staplingand cutting instrument in accordance with at least one embodiment;

FIG. 76 illustrates the electromagnetic lockout mechanism of FIG. 75 ina locked configuration;

FIG. 77 illustrates the electromagnetic lockout mechanism of FIG. 75 inan unlocked configuration;

FIG. 78 is a circuit diagram of an electrical circuit in accordance withat least one embodiment;

FIG. 79 is a circuit diagram of an electrical circuit of a poweredsurgical stapling and cutting instrument in accordance with at least oneembodiment;

FIG. 79A is an electrical circuit configured to detect the position andprogression of a staple firing member illustrating the staple firingmember in a fully fired position;

FIG. 79B illustrates the staple firing member of FIG. 79A in a fullyretracted position;

FIG. 80 is a perspective view of a powered surgical stapling and cuttinginstrument comprising a power assembly, a handle assembly, and aninterchangeable shaft assembly;

FIG. 81 is perspective view of the surgical instrument of FIG. 80 withthe interchangeable shaft assembly separated from the handle assembly;

FIGS. 82A and 82B depict a circuit diagram of the surgical instrument ofFIG. 80;

FIG. 83 is a circuit diagram of a powered surgical stapling and cuttinginstrument in accordance with at least one embodiment;

FIG. 84A is a circuit diagram of a powered surgical stapling and cuttinginstrument in accordance with at least one embodiment;

FIG. 84B illustrates minimum and maximum thresholds of current drawn bya motor of a powered surgical stapling and cutting instrument inaccordance with at least one embodiment;

FIG. 85 is circuit diagram illustrating a beginning-of-stroke switchcircuit and an end-of-stroke switch circuit with at least oneembodiment;

FIG. 86 is logic diagram illustrating a failure response system inaccordance with at least one embodiment;

FIG. 87 is logic diagram illustrating a failure response system inaccordance with at least one embodiment;

FIG. 88 is logic diagram illustrating a failure response system inaccordance with at least one embodiment; and

FIG. 89 is logic diagram illustrating a failure response system inaccordance with at least one embodiment.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/386,185, entitled SURGICAL STAPLINGINSTRUMENTS AND REPLACEABLE TOOL ASSEMBLIES THEREOF;

U.S. patent application Ser. No. 15/386,230, entitled ARTICULATABLESURGICAL STAPLING INSTRUMENTS;

U.S. patent application Ser. No. 15/386,221, entitled LOCKOUTARRANGEMENTS FOR SURGICAL END EFFECTORS;

U.S. patent application Ser. No. 15/386,209, entitled SURGICAL ENDEFFECTORS AND FIRING MEMBERS THEREOF;

U.S. patent application Ser. No. 15/386,198, entitled LOCKOUTARRANGEMENTS FOR SURGICAL END EFFECTORS AND REPLACEABLE TOOL ASSEMBLIES;and

U.S. patent application Ser. No. 15/386,240, entitled SURGICAL ENDEFFECTORS AND ADAPTABLE FIRING MEMBERS THEREFOR.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,939, entitled STAPLE CARTRIDGESAND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN;

U.S. patent application Ser. No. 15/385,941, entitled SURGICAL TOOLASSEMBLIES WITH CLUTCHING ARRANGEMENTS FOR SHIFTING BETWEEN CLOSURESYSTEMS WITH CLOSURE STROKE REDUCTION FEATURES AND ARTICULATION ANDFIRING SYSTEMS;

U.S. patent application Ser. No. 15/385,943, entitled SURGICAL STAPLINGINSTRUMENTS AND STAPLE-FORMING ANVILS;

U.S. patent application Ser. No. 15/385,950, entitled SURGICAL TOOLASSEMBLIES WITH CLOSURE STROKE REDUCTION FEATURES;

U.S. patent application Ser. No. 15/385,945, entitled STAPLE CARTRIDGESAND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN;

U.S. patent application Ser. No. 15/385,946, entitled SURGICAL STAPLINGINSTRUMENTS AND STAPLE-FORMING ANVILS;

U.S. patent application Ser. No. 15/385,951, entitled SURGICALINSTRUMENTS WITH JAW OPENING FEATURES FOR INCREASING A JAW OPENINGDISTANCE;

U.S. patent application Ser. No. 15/385,953, entitled METHODS OFSTAPLING TISSUE;

U.S. patent application Ser. No. 15/385,954, entitled FIRING MEMBERSWITH NON-PARALLEL JAW ENGAGEMENT FEATURES FOR SURGICAL END EFFECTORS;

U.S. patent application Ser. No. 15/385,955, entitled SURGICAL ENDEFFECTORS WITH EXPANDABLE TISSUE STOP ARRANGEMENTS;

U.S. patent application Ser. No. 15/385,948, entitled SURGICAL STAPLINGINSTRUMENTS AND STAPLE-FORMING ANVILS;

U.S. patent application Ser. No. 15/385,956, entitled SURGICALINSTRUMENTS WITH POSITIVE JAW OPENING FEATURES;

U.S. patent application Ser. No. 15/385,958, entitled SURGICALINSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTING FIRING SYSTEMACTUATION UNLESS AN UNSPENT STAPLE CARTRIDGE IS PRESENT; and

U.S. patent application Ser. No. 15/385,947, entitled STAPLE CARTRIDGESAND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,896, entitled METHOD FORRESETTING A FUSE OF A SURGICAL INSTRUMENT SHAFT;

U.S. patent application Ser. No. 15/385,898, entitled STAPLE FORMINGPOCKET ARRANGEMENT TO ACCOMMODATE DIFFERENT TYPES OF STAPLES;

U.S. patent application Ser. No. 15/385,899, entitled SURGICALINSTRUMENT COMPRISING IMPROVED JAW CONTROL;

U.S. patent application Ser. No. 15/385,901, entitled STAPLE CARTRIDGEAND STAPLE CARTRIDGE CHANNEL COMPRISING WINDOWS DEFINED THEREIN;

U.S. patent application Ser. No. 15/385,902, entitled SURGICALINSTRUMENT COMPRISING A CUTTING MEMBER;

U.S. patent application Ser. No. 15/385,904, entitled STAPLE FIRINGMEMBER COMPRISING A MISSING CARTRIDGE AND/OR SPENT CARTRIDGE LOCKOUT;

U.S. patent application Ser. No. 15/385,905, entitled FIRING ASSEMBLYCOMPRISING A LOCKOUT;

U.S. patent application Ser. No. 15/385,907, entitled SURGICALINSTRUMENT SYSTEM COMPRISING AN END EFFECTOR LOCKOUT AND A FIRINGASSEMBLY LOCKOUT;

U.S. patent application Ser. No. 15/385,908, entitled FIRING ASSEMBLYCOMPRISING A FUSE; and

U.S. patent application Ser. No. 15/385,909, entitled FIRING ASSEMBLYCOMPRISING A MULTIPLE FAILED-STATE FUSE.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,920, entitled STAPLE FORMINGPOCKET ARRANGEMENTS;

U.S. patent application Ser. No. 15/385,913, entitled ANVIL ARRANGEMENTSFOR SURGICAL STAPLERS;

U.S. patent application Ser. No. 15/385,914, entitled METHOD OFDEFORMING STAPLES FROM TWO DIFFERENT TYPES OF STAPLE CARTRIDGES WITH THESAME SURGICAL STAPLING INSTRUMENT;

U.S. patent application Ser. No. 15/385,893, entitled BILATERALLYASYMMETRIC STAPLE FORMING POCKET PAIRS;

U.S. patent application Ser. No. 15/385,929, entitled CLOSURE MEMBERSWITH CAM SURFACE ARRANGEMENTS FOR SURGICAL INSTRUMENTS WITH SEPARATE ANDDISTINCT CLOSURE AND FIRING SYSTEMS;

U.S. patent application Ser. No. 15/385,911, entitled SURGICAL STAPLERSWITH INDEPENDENTLY ACTUATABLE CLOSING AND FIRING SYSTEMS;

U.S. patent application Ser. No. 15/385,927, entitled SURGICAL STAPLINGINSTRUMENTS WITH SMART STAPLE CARTRIDGES;

U.S. patent application Ser. No. 15/385,917, entitled STAPLE CARTRIDGECOMPRISING STAPLES WITH DIFFERENT CLAMPING BREADTHS;

U.S. patent application Ser. No. 15/385,900, entitled STAPLE FORMINGPOCKET ARRANGEMENTS COMPRISING PRIMARY SIDEWALLS AND POCKET SIDEWALLS;

U.S. patent application Ser. No. 15/385,931, entitled NO-CARTRIDGE ANDSPENT CARTRIDGE LOCKOUT ARRANGEMENTS FOR SURGICAL STAPLERS;

U.S. patent application Ser. No. 15/385,915, entitled FIRING MEMBER PINANGLE;

U.S. patent application Ser. No. 15/385,897, entitled STAPLE FORMINGPOCKET ARRANGEMENTS COMPRISING ZONED FORMING SURFACE GROOVES;

U.S. patent application Ser. No. 15/385,922, entitled SURGICALINSTRUMENT WITH MULTIPLE FAILURE RESPONSE MODES;

U.S. patent application Ser. No. 15/385,912, entitled SURGICALINSTRUMENTS WITH JAWS THAT ARE PIVOTABLE ABOUT A FIXED AXIS AND INCLUDESEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS;

U.S. patent application Ser. No. 15/385,910, entitled ANVIL HAVING AKNIFE SLOT WIDTH;

U.S. patent application Ser. No. 15/385,903, entitled CLOSURE MEMBERARRANGEMENTS FOR SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 15/385,906, entitled FIRING MEMBER PINCONFIGURATIONS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/386,188, entitled STEPPED STAPLECARTRIDGE WITH ASYMMETRICAL STAPLES;

U.S. patent application Ser. No. 15/386,192, entitled STEPPED STAPLECARTRIDGE WITH TISSUE RETENTION AND GAP SETTING FEATURES;

U.S. patent application Ser. No. 15/386,206, entitled STAPLE CARTRIDGEWITH DEFORMABLE DRIVER RETENTION FEATURES;

U.S. patent application Ser. No. 15/386,226, entitled DURABILITYFEATURES FOR END EFFECTORS AND FIRING ASSEMBLIES OF SURGICAL STAPLINGINSTRUMENTS;

U.S. patent application Ser. No. 15/386,222, entitled SURGICAL STAPLINGINSTRUMENTS HAVING END EFFECTORS WITH POSITIVE OPENING FEATURES; and

U.S. patent application Ser. No. 15/386,236, entitled CONNECTIONPORTIONS FOR DISPOSABLE LOADING UNITS FOR SURGICAL STAPLING INSTRUMENTS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,887, entitled METHOD FORATTACHING A SHAFT ASSEMBLY TO A SURGICAL INSTRUMENT AND, ALTERNATIVELY,TO A SURGICAL ROBOT;

U.S. patent application Ser. No. 15/385,889, entitled SHAFT ASSEMBLYCOMPRISING A MANUALLY-OPERABLE RETRACTION SYSTEM FOR USE WITH AMOTORIZED SURGICAL INSTRUMENT SYSTEM;

U.S. patent application Ser. No. 15/385,890, entitled SHAFT ASSEMBLYCOMPRISING SEPARATELY ACTUATABLE AND RETRACTABLE SYSTEMS;

U.S. patent application Ser. No. 15/385,891, entitled SHAFT ASSEMBLYCOMPRISING A CLUTCH CONFIGURED TO ADAPT THE OUTPUT OF A ROTARY FIRINGMEMBER TO TWO DIFFERENT SYSTEMS;

U.S. patent application Ser. No. 15/385,892, entitled SURGICAL SYSTEMCOMPRISING A FIRING MEMBER ROTATABLE INTO AN ARTICULATION STATE TOARTICULATE AN END EFFECTOR OF THE SURGICAL SYSTEM;

U.S. patent application Ser. No. 15/385,894, entitled SHAFT ASSEMBLYCOMPRISING A LOCKOUT; and

U.S. patent application Ser. No. 15/385,895, entitled SHAFT ASSEMBLYCOMPRISING FIRST AND SECOND ARTICULATION LOCKOUTS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,916, entitled SURGICAL STAPLINGSYSTEMS;

U.S. patent application Ser. No. 15/385,918, entitled SURGICAL STAPLINGSYSTEMS;

U.S. patent application Ser. No. 15/385,919, entitled SURGICAL STAPLINGSYSTEMS;

U.S. patent application Ser. No. 15/385,921, entitled SURGICAL STAPLECARTRIDGE WITH MOVABLE CAMMING MEMBER CONFIGURED TO DISENGAGE FIRINGMEMBER LOCKOUT FEATURES;

U.S. patent application Ser. No. 15/385,923, entitled SURGICAL STAPLINGSYSTEMS;

U.S. patent application Ser. No. 15/385,925, entitled JAW ACTUATED LOCKARRANGEMENTS FOR PREVENTING ADVANCEMENT OF A FIRING MEMBER IN A SURGICALEND EFFECTOR UNLESS AN UNFIRED CARTRIDGE IS INSTALLED IN THE ENDEFFECTOR;

U.S. patent application Ser. No. 15/385,926, entitled AXIALLY MOVABLECLOSURE SYSTEM ARRANGEMENTS FOR APPLYING CLOSURE MOTIONS TO JAWS OFSURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 15/385,928, entitled PROTECTIVE COVERARRANGEMENTS FOR A JOINT INTERFACE BETWEEN A MOVABLE JAW AND ACTUATORSHAFT OF A SURGICAL INSTRUMENT;

U.S. patent application Ser. No. 15/385,930, entitled SURGICAL ENDEFFECTOR WITH TWO SEPARATE COOPERATING OPENING FEATURES FOR OPENING ANDCLOSING END EFFECTOR JAWS;

U.S. patent application Ser. No. 15/385,932, entitled ARTICULATABLESURGICAL END EFFECTOR WITH ASYMMETRIC SHAFT ARRANGEMENT;

U.S. patent application Ser. No. 15/385,933, entitled ARTICULATABLESURGICAL INSTRUMENT WITH INDEPENDENT PIVOTABLE LINKAGE DISTAL OF ANARTICULATION LOCK;

U.S. patent application Ser. No. 15/385,934, entitled ARTICULATION LOCKARRANGEMENTS FOR LOCKING AN END EFFECTOR IN AN ARTICULATED POSITION INRESPONSE TO ACTUATION OF A JAW CLOSURE SYSTEM;

U.S. patent application Ser. No. 15/385,935, entitled LATERALLYACTUATABLE ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END EFFECTOR OFA SURGICAL INSTRUMENT IN AN ARTICULATED CONFIGURATION; and

U.S. patent application Ser. No. 15/385,936, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH ARTICULATION STROKE AMPLIFICATION FEATURES.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/191,775, entitled STAPLE CARTRIDGECOMPRISING WIRE STAPLES AND STAMPED STAPLES;

U.S. patent application Ser. No. 15/191,807, entitled STAPLING SYSTEMFOR USE WITH WIRE STAPLES AND STAMPED STAPLES;

U.S. patent application Ser. No. 15/191,834, entitled STAMPED STAPLESAND STAPLE CARTRIDGES USING THE SAME;

U.S. patent application Ser. No. 15/191,788, entitled STAPLE CARTRIDGECOMPRISING OVERDRIVEN STAPLES; and

U.S. patent application Ser. No. 15/191,818, entitled STAPLE CARTRIDGECOMPRISING OFFSET LONGITUDINAL STAPLE ROWS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. Design Patent Application Serial No. 29/569,218, entitled SURGICALFASTENER;

U.S. Design Patent Application Serial No. 29/569,227, entitled SURGICALFASTENER;

U.S. Design Patent Application Serial No. 29/569,259, entitled SURGICALFASTENER CARTRIDGE; and

U.S. Design Patent Application Serial No. 29/569,264, entitled SURGICALFASTENER CARTRIDGE.

Applicant of the present application owns the following patentapplications that were filed on Apr. 1, 2016 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 15/089,325, entitled METHOD FOROPERATING A SURGICAL STAPLING SYSTEM;

U.S. patent application Ser. No. 15/089,321, entitled MODULAR SURGICALSTAPLING SYSTEM COMPRISING A DISPLAY;

U.S. patent application Ser. No. 15/089,326, entitled SURGICAL STAPLINGSYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE DISPLAY FIELD;

U.S. patent application Ser. No. 15/089,263, entitled SURGICALINSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIP PORTION;

U.S. patent application Ser. No. 15/089,262, entitled ROTARY POWEREDSURGICAL INSTRUMENT WITH MANUALLY ACTUATABLE BAILOUT SYSTEM;

U.S. patent application Ser. No. 15/089,277, entitled SURGICAL CUTTINGAND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE MEMBER;

U.S. patent application Ser. No. 15/089,296, entitled INTERCHANGEABLESURGICAL TOOL ASSEMBLY WITH A SURGICAL END EFFECTOR THAT IS SELECTIVELYROTATABLE ABOUT A SHAFT AXIS;

U.S. patent application Ser. No. 15/089,258, entitled SURGICAL STAPLINGSYSTEM COMPRISING A SHIFTABLE TRANSMISSION;

U.S. patent application Ser. No. 15/089,278, entitled SURGICAL STAPLINGSYSTEM CONFIGURED TO PROVIDE SELECTIVE CUTTING OF TISSUE;

U.S. patent application Ser. No. 15/089,284, entitled SURGICAL STAPLINGSYSTEM COMPRISING A CONTOURABLE SHAFT;

U.S. patent application Ser. No. 15/089,295, entitled SURGICAL STAPLINGSYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT;

U.S. patent application Ser. No. 15/089,300, entitled SURGICAL STAPLINGSYSTEM COMPRISING AN UNCLAMPING LOCKOUT;

U.S. patent application Ser. No. 15/089,196, entitled SURGICAL STAPLINGSYSTEM COMPRISING A JAW CLOSURE LOCKOUT;

U.S. patent application Ser. No. 15/089,203, entitled SURGICAL STAPLINGSYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT;

U.S. patent application Ser. No. 15/089,210, entitled SURGICAL STAPLINGSYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT;

U.S. patent application Ser. No. 15/089,324, entitled SURGICALINSTRUMENT COMPRISING A SHIFTING MECHANISM;

U.S. patent application Ser. No. 15/089,335, entitled SURGICAL STAPLINGINSTRUMENT COMPRISING MULTIPLE LOCKOUTS;

U.S. patent application Ser. No. 15/089,339, entitled SURGICAL STAPLINGINSTRUMENT;

U.S. patent application Ser. No. 15/089,253, entitled SURGICAL STAPLINGSYSTEM CONFIGURED TO APPLY ANNULAR ROWS OF STAPLES HAVING DIFFERENTHEIGHTS;

U.S. patent application Ser. No. 15/089,304, entitled SURGICAL STAPLINGSYSTEM COMPRISING A GROOVED FORMING POCKET;

U.S. patent application Ser. No. 15/089,331, entitled ANVIL MODIFICATIONMEMBERS FOR SURGICAL STAPLERS;

U.S. patent application Ser. No. 15/089,336, entitled STAPLE CARTRIDGESWITH ATRAUMATIC FEATURES;

U.S. patent application Ser. No. 15/089,312, entitled CIRCULAR STAPLINGSYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT;

U.S. patent application Ser. No. 15/089,309, entitled CIRCULAR STAPLINGSYSTEM COMPRISING ROTARY FIRING SYSTEM; and

U.S. patent application Ser. No. 15/089,349, entitled CIRCULAR STAPLINGSYSTEM COMPRISING LOAD CONTROL.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Dec. 31, 2015 whichare each herein incorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/984,488, entitled MECHANISMS FORCOMPENSATING FOR BATTERY PACK FAILURE IN POWERED SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 14/984,525, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 14/984,552, entitled SURGICALINSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROL CIRCUITS.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 9, 2016 which areeach herein incorporated by reference in their respective entirety:

U.S. patent application Ser. No. 15/019,220, entitled SURGICALINSTRUMENT WITH ARTICULATING AND AXIALLY TRANSLATABLE END EFFECTOR;

U.S. patent application Ser. No. 15/019,228, entitled SURGICALINSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS;

U.S. patent application Ser. No. 15/019,196, entitled SURGICALINSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY CONSTRAINT;

U.S. patent application Ser. No. 15/019,206, entitled SURGICALINSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLY ARTICULATABLE RELATIVETO AN ELONGATE SHAFT ASSEMBLY;

U.S. patent application Ser. No. 15/019,215, entitled SURGICALINSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS;

U.S. patent application Ser. No. 15/019,227, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH SINGLE ARTICULATION LINK ARRANGEMENTS;

U.S. patent application Ser. No. 15/019,235, entitled SURGICALINSTRUMENTS WITH TENSIONING ARRANGEMENTS FOR CABLE DRIVEN ARTICULATIONSYSTEMS;

U.S. patent application Ser. No. 15/019,230, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAM ARRANGEMENTS; and

U.S. patent application Ser. No. 15/019,245, entitled SURGICALINSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 12, 2016 whichare each herein incorporated by reference in their respective entirety:

U.S. patent application Ser. No. 15/043,254, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 15/043,259, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 15/043,275, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 15/043,289, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Jun. 18, 2015 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/742,925, entitled SURGICAL ENDEFFECTORS WITH POSITIVE JAW OPENING ARRANGEMENTS;

U.S. patent application Ser. No. 14/742,941, entitled SURGICAL ENDEFFECTORS WITH DUAL CAM ACTUATED JAW CLOSING FEATURES;

U.S. patent application Ser. No. 14/742,914, entitled MOVABLE FIRINGBEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 14/742,900, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAM STRUCTURES WITH CENTERFIRING SUPPORT MEMBER FOR ARTICULATION SUPPORT;

U.S. patent application Ser. No. 14/742,885, entitled DUAL ARTICULATIONDRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 14/742,876, entitled PUSH/PULLARTICULATION DRIVE SYSTEMS FOR ARTICULATABLE SURGICAL INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Mar. 6, 2015 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/640,746, entitled POWERED SURGICALINSTRUMENT, now U.S. Patent Application Publication No. 2016/0256184;

U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE LEVELTHRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL INSTRUMENTS, now U.S.Patent Application Publication No. 2016/02561185;

U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE TISSUECOMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR MULTIPLE TISSUETYPES, now U.S. Patent Application Publication No. 2016/0256154;

U.S. patent application Ser. No. 14/640,935, entitled OVERLAID MULTISENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE TISSUECOMPRESSION, now U.S. Patent Application Publication No. 2016/0256071;

U.S. patent application Ser. No. 14/640,831, entitled MONITORING SPEEDCONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED SURGICALINSTRUMENTS, now U.S. Patent Application Publication No. 2016/0256153;

U.S. patent application Ser. No. 14/640,859, entitled TIME DEPENDENTEVALUATION OF SENSOR DATA TO DETERMINE STABILITY, CREEP, ANDVISCOELASTIC ELEMENTS OF MEASURES, now U.S. Patent ApplicationPublication No. 2016/0256187;

U.S. patent application Ser. No. 14/640,817, entitled INTERACTIVEFEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2016/0256186;

U.S. patent application Ser. No. 14/640,844, entitled CONTROL TECHNIQUESAND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH SELECT CONTROLPROCESSING FROM HANDLE, now U.S. Patent Application Publication No.2016/0256155;

U.S. patent application Ser. No. 14/640,837, entitled SMART SENSORS WITHLOCAL SIGNAL PROCESSING, now U.S. Patent Application Publication No.2016/0256163;

U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FORDETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A SURGICALSTAPLER, now U.S. Patent Application Publication No. 2016/0256160;

U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND POWERCOMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT, now U.S. PatentApplication Publication No. 2016/0256162; and

U.S. patent application Ser. No. 14/640,780, entitled SURGICALINSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING, now U.S. PatentApplication Publication No. 2016/0256161.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/633,576, entitled SURGICALINSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION, now U.S. PatentApplication Publication No. 2016/0249919;

U.S. patent application Ser. No. 14/633,546, entitled SURGICAL APPARATUSCONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER OF THE SURGICALAPPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE BAND, now U.S. PatentApplication Publication No. 2016/0249915;

U.S. patent application Ser. No. 14/633,560, entitled SURGICAL CHARGINGSYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE BATTERIES, now U.S.Patent Application Publication No. 2016/0249910;

U.S. patent application Ser. No. 14/633,566, entitled CHARGING SYSTEMTHAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A BATTERY, now U.S.Patent Application Publication No. 2016/0249918;

U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FORMONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED, now U.S.Patent Application Publication No. 2016/0249916;

U.S. patent application Ser. No. 14/633,542, entitled REINFORCED BATTERYFOR A SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.2016/0249908;

U.S. patent application Ser. No. 14/633,548, entitled POWER ADAPTER FORA SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.2016/0249909;

U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE SURGICALINSTRUMENT HANDLE, now U.S. Patent Application Publication No.2016/0249945;

U.S. patent application Ser. No. 14/633,541, entitled MODULAR STAPLINGASSEMBLY, now U.S. Patent Application Publication No. 2016/0249927; and

U.S. patent application Ser. No. 14/633,562, entitled SURGICAL APPARATUSCONFIGURED TO TRACK AN END-OF-LIFE PARAMETER, now U.S. PatentApplication Publication No. 2016/0249917.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/574,478, entitled SURGICALINSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND MEANSFOR ADJUSTING THE FIRING STROKE OF A FIRING MEMBER, now U.S. PatentApplication Publication No. 2016/0174977;

U.S. patent application Ser. No. 14/574,483, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS, now U.S. PatentApplication Publication No. 2016/0174969;

U.S. patent application Ser. No. 14/575,139, entitled DRIVE ARRANGEMENTSFOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2016/0174978;

U.S. patent application Ser. No. 14/575,148, entitled LOCKINGARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE SURGICALEND EFFECTORS, now U.S. Patent Application Publication No. 2016/0174976;

U.S. patent application Ser. No. 14/575,130, entitled SURGICALINSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A DISCRETENON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE, now U.S. PatentApplication Publication No. 2016/0174972;

U.S. patent application Ser. No. 14/575,143, entitled SURGICALINSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS, now U.S. PatentApplication Publication No. 2016/0174983;

U.S. patent application Ser. No. 14/575,117, entitled SURGICALINSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING BEAMSUPPORT ARRANGEMENTS, now U.S. Patent Application Publication No.2016/0174975;

U.S. patent application Ser. No. 14/575,154, entitled SURGICALINSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING BEAMSUPPORT ARRANGEMENTS, now U.S. Patent Application Publication No.2016/0174973;

U.S. patent application Ser. No. 14/574,493, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM, now U.S.Patent Application Publication No. 2016/0174970; and

U.S. patent application Ser. No. 14/574,500, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM, now U.S.Patent Application Publication No. 2016/0174971.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 13/782,295, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION,now U.S. Patent Application Publication No. 2014/0246471;

U.S. patent application Ser. No. 13/782,323, entitled ROTARY POWEREDARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2014/0246472;

U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL SWITCHARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2014/0249557;

U.S. patent application Ser. No. 13/782,499, entitled ELECTROMECHANICALSURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT, now U.S. Pat. No.9,358,003;

U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE PROCESSORMOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2014/0246478;

U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK SWITCHASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,326,767;

U.S. patent application Ser. No. 13/782,481, entitled SENSORSTRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now U.S. Pat.No. 9,468,438;

U.S. patent application Ser. No. 13/782,518, entitled CONTROL METHODSFOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS, now U.S.

Patent Application Publication No. 2014/0246475;

U.S. patent application Ser. No. 13/782,375, entitled ROTARY POWEREDSURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM, now U.S. Pat. No.9,398,911; and

U.S. patent application Ser. No. 13/782,536, entitled SURGICALINSTRUMENT SOFT STOP, now U.S. Pat. No. 9,307,986.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 13/803,097, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now U.S. PatentApplication Publication No. 2014/0263542;

U.S. patent application Ser. No. 13/803,193, entitled CONTROLARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now U.S. Pat.No. 9,332,987;

U.S. patent application Ser. No. 13/803,053, entitled INTERCHANGEABLESHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT, now U.S. PatentApplication Publication No. 2014/0263564;

U.S. patent application Ser. No. 13/803,086, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. PatentApplication Publication No. 2014/0263541;

U.S. patent application Ser. No. 13/803,210, entitled SENSORARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS,now U.S. Patent Application Publication No. 2014/0263538;

U.S. patent application Ser. No. 13/803,148, entitled MULTI-FUNCTIONMOTOR FOR A SURGICAL INSTRUMENT, now U.S. Patent Application PublicationNo. 2014/0263554;

U.S. patent application Ser. No. 13/803,066, entitled DRIVE SYSTEMLOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2014/0263565;

U.S. patent application Ser. No. 13/803,117, entitled ARTICULATIONCONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,726;

U.S. patent application Ser. No. 13/803,130, entitled DRIVE TRAINCONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,727; and

U.S. patent application Ser. No. 13/803,159, entitled METHOD AND SYSTEMFOR OPERATING A SURGICAL INSTRUMENT, now U.S. Patent ApplicationPublication No. 2014/0277017.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

U.S. patent application Ser. No. 14/200,111, entitled CONTROL SYSTEMSFOR SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No.2014/0263539.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/226,106, entitled POWER MANAGEMENTCONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2015/0272582;

U.S. patent application Ser. No. 14/226,099, entitled STERILIZATIONVERIFICATION CIRCUIT, now U.S. Patent Application Publication No.2015/0272581;

U.S. patent application Ser. No. 14/226,094, entitled VERIFICATION OFNUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT, now U.S. Patent ApplicationPublication No. 2015/0272580;

U.S. patent application Ser. No. 14/226,117, entitled POWER MANAGEMENTTHROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP CONTROL, now U.S.Patent Application Publication No. 2015/0272574;

U.S. patent application Ser. No. 14/226,075, entitled MODULAR POWEREDSURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES, now U.S. PatentApplication Publication No. 2015/0272579;

U.S. patent application Ser. No. 14/226,093, entitled FEEDBACKALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S.Patent Application Publication No. 2015/0272569;

U.S. patent application Ser. No. 14/226,116, entitled SURGICALINSTRUMENT UTILIZING SENSOR ADAPTATION, now U.S. Patent ApplicationPublication No. 2015/0272571;

U.S. patent application Ser. No. 14/226,071, entitled SURGICALINSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR, now U.S. PatentApplication Publication No. 2015/0272578;

U.S. patent application Ser. No. 14/226,097, entitled SURGICALINSTRUMENT COMPRISING INTERACTIVE SYSTEMS, now U.S. Patent ApplicationPublication No. 2015/0272570;

U.S. patent application Ser. No. 14/226,126, entitled INTERFACE SYSTEMSFOR USE WITH SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2015/0272572;

U.S. patent application Ser. No. 14/226,133, entitled MODULAR SURGICALINSTRUMENT SYSTEM, now U.S. Patent Application Publication No.2015/0272557;

U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS ANDMETHODS FOR CONTROLLING A SEGMENTED CIRCUIT, now U.S. Patent ApplicationPublication No. 2015/0277471;

U.S. patent application Ser. No. 14/226,076, entitled POWER MANAGEMENTTHROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE PROTECTION, now U.S.

Patent Application Publication No. 2015/0280424;

U.S. patent application Ser. No. 14/226,111, entitled SURGICAL STAPLINGINSTRUMENT SYSTEM, now U.S. Patent Application Publication No.2015/0272583; and

U.S. patent application Ser. No. 14/226,125, entitled SURGICALINSTRUMENT COMPRISING A ROTATABLE SHAFT, now U.S. Patent ApplicationPublication No. 2015/0280384.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY ANDSENSORS FOR POWERED MEDICAL DEVICE, now U.S. Patent ApplicationPublication No. 2016/0066912;

U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT WITHINTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION, now U.S. PatentApplication Publication No. 2016/0066914;

U.S. patent application Ser. No. 14/478,908, entitled MONITORING DEVICEDEGRADATION BASED ON COMPONENT EVALUATION, now U.S. Patent ApplicationPublication No. 2016/0066910;

U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE SENSORSWITH ONE SENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR INTERPRETATION,now U.S. Patent Application Publication No. 2016/0066909;

U.S. patent application Ser. No. 14/479,110, entitled POLARITY OF HALLMAGNET TO DETECT MISLOADED CARTRIDGE, now U.S. Patent ApplicationPublication No. 2016/0066915;

U.S. patent application Ser. No. 14/479,098, entitled SMART CARTRIDGEWAKE UP OPERATION AND DATA RETENTION, now U.S. Patent ApplicationPublication No. 2016/0066911;

U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE MOTORCONTROL FOR POWERED MEDICAL DEVICE, now U.S. Patent ApplicationPublication No. 2016/0066916; and

U.S. patent application Ser. No. 14/479,108, entitled LOCAL DISPLAY OFTISSUE PARAMETER STABILIZATION, now U.S. Patent Application PublicationNo. 2016/0066913.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entirety:

U.S. patent application Ser. No. 14/248,590, entitled MOTOR DRIVENSURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now U.S. PatentApplication Publication No. 2014/0305987;

U.S. patent application Ser. No. 14/248,581, entitled SURGICALINSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE OPERATED FROMTHE SAME ROTATABLE OUTPUT, now U.S. Patent Application Publication No.2014/0305989;

U.S. patent application Ser. No. 14/248,595, entitled SURGICALINSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE OPERATION OF THESURGICAL INSTRUMENT, now U.S. Patent Application Publication No.2014/0305988;

U.S. patent application Ser. No. 14/248,588, entitled POWERED LINEARSURGICAL STAPLER, now U.S. Patent Application Publication No.2014/0309666;

U.S. patent application Ser. No. 14/248,591, entitled TRANSMISSIONARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. Patent ApplicationPublication No. 2014/0305991;

U.S. patent application Ser. No. 14/248,584, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING ROTARYDRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS, now U.S. PatentApplication Publication No. 2014/0305994;

U.S. patent application Ser. No. 14/248,587, entitled POWERED SURGICALSTAPLER, now U.S. Patent Application Publication No. 2014/0309665;

U.S. patent application Ser. No. 14/248,586, entitled DRIVE SYSTEMDECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. PatentApplication Publication No. 2014/0305990; and

U.S. patent application Ser. No. 14/248,607, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS, nowU.S. Patent Application Publication No. 2014/0305992.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entirety:

U.S. Provisional Patent Application Ser. No. 61/812,365, entitledSURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR;

U.S. Provisional Patent Application Ser. No. 61/812,376, entitled LINEARCUTTER WITH POWER;

U.S. Provisional Patent Application Ser. No. 61/812,382, entitled LINEARCUTTER WITH MOTOR AND PISTOL GRIP;

U.S. Provisional Patent Application Ser. No. 61/812,385, entitledSURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION MOTORS AND MOTORCONTROL; and

U.S. Provisional Patent Application Ser. No. 61/812,372, entitledSURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

FIG. 1 depicts a motor-driven surgical system 10 that may be used toperform a variety of different surgical procedures. As can be seen inthat Figure, one example of the surgical system 10 includes fourinterchangeable surgical tool assemblies 100, 200, 300 and 1000 that areeach adapted for interchangeable use with a handle assembly 500. Eachinterchangeable surgical tool assembly 100, 200, 300 and 1000 may bedesigned for use in connection with the performance of one or morespecific surgical procedures. In another surgical system embodiment, theinterchangeable surgical tool assemblies may be effectively employedwith a tool drive assembly of a robotically controlled or automatedsurgical system. For example, the surgical tool assemblies disclosedherein may be employed with various robotic systems, instruments,components and methods such as, but not limited to, those disclosed inU.S. Pat. No. 9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITHROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which is hereby incorporatedby reference herein in its entirety.

FIG. 2 illustrates one form of an interchangeable surgical tool assembly100 that is operably coupled to the handle assembly 500. FIG. 3illustrates attachment of the interchangeable surgical tool assembly 100to the handle assembly 500. The attachment arrangement and processdepicted in FIG. 3 may also be employed in connection with attachment ofany of the interchangeable surgical tool assemblies 100, 200, 300 and1000 to a tool drive portion or tool drive housing of a robotic system.The handle assembly 500 may comprise a handle housing 502 that includesa pistol grip portion 504 that can be gripped and manipulated by theclinician. As will be briefly discussed below, the handle assembly 500operably supports a plurality of drive systems that are configured togenerate and apply various control motions to corresponding portions ofthe interchangeable surgical tool assembly 100, 200, 300 and/or 1000that is operably attached thereto.

Referring now to FIG. 3, the handle assembly 500 may further include aframe 506 that operably supports the plurality of drive systems. Forexample, the frame 506 can operably support a “first” or closure drivesystem, generally designated as 510, which may be employed to applyclosing and opening motions to the interchangeable surgical toolassembly 100, 200, 300 and 1000 that is operably attached or coupled tothe handle assembly 500. In at least one form, the closure drive system510 may include an actuator in the form of a closure trigger 512 that ispivotally supported by the frame 506. Such arrangement enables theclosure trigger 512 to be manipulated by a clinician such that when theclinician grips the pistol grip portion 504 of the handle assembly 500,the closure trigger 512 may be easily pivoted from a starting or“unactuated” position to an “actuated” position and more particularly toa fully compressed or fully actuated position. In various forms, theclosure drive system 510 further includes a closure linkage assembly 514that is pivotally coupled to the closure trigger 512 or otherwiseoperably interfaces therewith. As will be discussed in further detailbelow, in the illustrated example, the closure linkage assembly 514includes a transverse attachment pin 516 that facilitates attachment toa corresponding drive system on the surgical tool assembly. In use, toactuate the closure drive system, the clinician depresses the closuretrigger 512 towards the pistol grip portion 504. As described in furtherdetail in U.S. patent application Ser. No. 14/226,142, entitled SURGICALINSTRUMENT COMPRISING A SENSOR SYSTEM, now U.S. Patent ApplicationPublication No. 2015/0272575, which is hereby incorporated by referencein its entirety herein, when the clinician fully depresses the closuretrigger 512 to attain the full closure stroke, the closure drive systemis configured to lock the closure trigger 512 into the fully depressedor fully actuated position. When the clinician desires to unlock theclosure trigger 512 to permit it to be biased to the unactuatedposition, the clinician simply activates a closure release buttonassembly 518 which enables the closure trigger to return to unactuatedposition. The closure release button 518 may also be configured tointeract with various sensors that communicate with a microcontroller520 in the handle assembly 500 for tracking the position of the closuretrigger 512. Further details concerning the configuration and operationof the closure release button assembly 518 may be found in U.S. PatentApplication Publication No. 2015/0272575.

In at least one form, the handle assembly 500 and the frame 506 mayoperably support another drive system referred to herein as a firingdrive system 530 that is configured to apply firing motions tocorresponding portions of the interchangeable surgical tool assemblythat is attached thereto. As was described in detail in U.S. PatentApplication Publication No. 2015/0272575, the firing drive system 530may employ an electric motor (not shown in FIGS. 1-3) that is located inthe pistol grip portion 504 of the handle assembly 500. In variousforms, the motor may be a DC brushed driving motor having a maximumrotation of, approximately, 25,000 RPM, for example. In otherarrangements, the motor may include a brushless motor, a cordless motor,a synchronous motor, a stepper motor, or any other suitable electricmotor. The motor may be powered by a power source 522 that in one formmay comprise a removable power pack. The power pack may support aplurality of Lithium Ion (“LI”) or other suitable batteries therein. Anumber of batteries may be connected in series may be used as the powersource 522 for the surgical system 10. In addition, the power source 522may be replaceable and/or rechargeable.

The electric motor is configured to axially drive a longitudinallymovable drive member 540 in a distal and proximal directions dependingupon the polarity of the motor. For example, when the motor is driven inone rotary direction, the longitudinally movable drive member 540 thewill be axially driven in the distal direction “DD”. When the motor isdriven in the opposite rotary direction, the longitudinally movabledrive member 540 will be axially driven in a proximal direction “PD”.The handle assembly 500 can include a switch 513 which can be configuredto reverse the polarity applied to the electric motor by the powersource 522 or otherwise control the motor. The handle assembly 500 canalso include a sensor or sensors (not shown) that is configured todetect the position of the drive member 540 and/or the direction inwhich the drive member 540 is being moved. Actuation of the motor can becontrolled by a firing trigger 532 (FIG. 1) that is pivotally supportedon the handle assembly 500. The firing trigger 532 may be pivotedbetween an unactuated position and an actuated position. The firingtrigger 532 may be biased into the unactuated position by a spring orother biasing arrangement such that when the clinician releases thefiring trigger 532, it may be pivoted or otherwise returned to theunactuated position by the spring or biasing arrangement. In at leastone form, the firing trigger 532 can be positioned “outboard” of theclosure trigger 512 as was discussed above. As discussed in U.S. PatentApplication Publication No. 2015/0272575, the handle assembly 500 may beequipped with a firing trigger safety button (not shown) to preventinadvertent actuation of the firing trigger 532. When the closuretrigger 512 is in the unactuated position, the safety button iscontained in the handle assembly 500 where the clinician cannot readilyaccess it and move it between a safety position preventing actuation ofthe firing trigger 532 and a firing position wherein the firing trigger532 may be fired. As the clinician depresses the closure trigger 512,the safety button and the firing trigger 532 pivot down wherein they canthen be manipulated by the clinician.

In at least one form, the longitudinally movable drive member 540 mayhave a rack of teeth (not shown) formed thereon for meshing engagementwith a corresponding drive gear arrangement (not shown) that interfaceswith the motor. Further details regarding those features may be found inU.S. Patent Application Publication No. 2015/0272575. At least one formalso includes a manually-actuatable “bailout” assembly that isconfigured to enable the clinician to manually retract thelongitudinally movable drive member 540 should the motor becomedisabled. The bailout assembly may include a lever or bailout handleassembly that is stored within the handle assembly 500 under areleasable door 550. The lever is configured to be manually pivoted intoratcheting engagement with the teeth in the drive member 540. Thus, theclinician can manually retract the drive member 540 by using the bailouthandle assembly to ratchet the drive member 5400 in the proximaldirection “PD”. U.S. patent application Ser. No. 12/249,117, entitledPOWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLYRETRACTABLE FIRING SYSTEM, now U.S. Pat. No. 8,608,045, the entiredisclosure of which is hereby incorporated by reference herein disclosesbailout arrangements and other components, arrangements and systems thatmay also be employed with the various surgical tool assemblies disclosedherein.

Turning now to FIG. 2, the interchangeable surgical tool assembly 100includes a surgical end effector 110 that comprises a first jaw and asecond jaw. In one arrangement, the first jaw comprises an elongatechannel 112 that is configured to operably support a surgical staplecartridge 116 therein. The second jaw comprises an anvil 114 that ispivotally supported relative to the elongate channel 112. Theinterchangeable surgical tool assembly 100 also includes a lockablearticulation joint 120 which can be configured to releasably hold theend effector 110 in a desired position relative to a shaft axis SA.Details regarding various constructions and operation of the endeffector 110, the articulation joint 120 and the articulation lock areset forth in U.S. patent application Ser. No. 13/803,086, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, nowU.S. Patent Application Publication No. 2014/0263541, which is herebyincorporated by reference herein in its entirety. As can be further seenin FIGS. 2 and 3, the interchangeable surgical tool assembly 100 caninclude a proximal housing or nozzle 130 and a closure tube assembly 140which can be utilized to close and/or open the anvil 114 of the endeffector 110. As discussed in U.S. Patent Application Publication No.2015/0272575, the closure tube assembly 140 is movably supported on aspine 145 which supports articulation driver arrangement 147 forapplying articulation motions to the surgical end effector 110. Thespine 145 is configured to, one, slidably support a firing bar 170therein and, two, slidably support the closure tube assembly 140 whichextends around the spine 145. In various circumstances, the spine 145includes a proximal end that is rotatably supported in a chassis 150.See FIG. 3. In one arrangement, for example, the proximal end of thespine 145 is attached to a spine bearing (not shown) that is configuredto be supported within the chassis 150. Such an arrangement facilitatesrotatable attachment of the spine 145 to the chassis 150 such that thespine 145 may be selectively rotated about a shaft axis SA relative tothe chassis 150.

Still referring to FIG. 3, the interchangeable surgical tool assembly100 includes a closure shuttle 160 that is slidably supported within thechassis 150 such that it may be axially moved relative thereto. As canbe seen in FIG. 3, the closure shuttle 160 includes a pair ofproximally-protruding hooks 162 that are configured for attachment tothe attachment pin 516 that is attached to the closure linkage assembly514 in the handle assembly 500. A proximal closure tube segment 146 ofthe closure tube assembly 140 is coupled to the closure shuttle 160 forrelative rotation thereto. Thus, when the hooks 162 are hooked over thepin 516, actuation of the closure trigger 512 will result in the axialmovement of the closure shuttle 160 and ultimately, the closure tubeassembly 140 on the spine 145. A closure spring (not shown) may also bejournaled on the closure tube assembly 140 and serves to bias theclosure tube assembly 140 in the proximal direction “PD” which can serveto pivot the closure trigger 512 into the unactuated position when theshaft assembly 100 is operably coupled to the handle assembly 500. Inuse, the closure tube assembly 140 is translated distally (direction DD)to close the anvil 114, for example, in response to the actuation of theclosure trigger 512. The closure tube assembly 140 includes a distalclosure tube segment 142 that is pivotally pinned to a distal end of aproximal closure tube segment 146. The distal closure tube segment 142is configured to axially move with the proximal closure tube segment 146relative to the surgical end effector 110. When the distal end of thedistal closure tube segment 142 strikes a proximal surface or ledge 115on the anvil 114, the anvil 114 is pivoted closed. Further detailsconcerning the closure of anvil 114 may be found in the aforementionedU.S. Patent Application Publication No. 2014/0263541 and will bediscussed in further detail below. As was also described in detail inU.S. Patent Application Publication No. 2014/0263541, the anvil 114 isopened by proximally translating the distal closure tube segment 142.The distal closure tube segment 142 has a horseshoe aperture 143 thereinthat defines a downwardly extending return tab (not shown) thatcooperates with an anvil tab 117 formed on the proximal end of the anvil114 to pivot the anvil 114 back to an open position. In the fully openposition, the closure tube assembly 140 is in its proximal-most orunactuated position.

As was also indicated above, the interchangeable surgical tool assembly100 further includes a firing bar 170 that is supported for axial travelwithin the shaft spine 145. The firing bar 170 includes an intermediatefiring shaft portion that is configured for attachment to a distalcutting portion or knife bar that is configured for axial travel throughthe surgical end effector 110. In at least one arrangement, theinterchangeable surgical tool assembly 100 includes a clutch assembly(not shown) which can be configured to selectively and releasably couplethe articulation driver to the firing bar 170. Further details regardingthe clutch assembly features and operation may be found in U.S. PatentApplication Publication No. 2014/0263541. As discussed in U.S. PatentApplication Publication No. 2014/0263541, when the clutch assembly is inits engaged position, distal movement of the firing bar 170 can move thearticulation driver arrangement 147 distally and, correspondingly,proximal movement of the firing bar 170 can move the articulation driverarrangement 147 proximally. When the clutch assembly is in itsdisengaged position, movement of the firing bar 170 is not transmittedto the articulation driver arrangement 147 and, as a result, the firingbar 170 can move independently of the articulation driver arrangement147. The interchangeable surgical tool assembly 100 may also include aslip ring assembly (not shown) which can be configured to conductelectrical power to and/or from the end effector 110 and/or communicatesignals to and/or from the end effector 110. Further details regardingthe slip ring assembly may be found in U.S. Patent ApplicationPublication No. 2014/0263541. U.S. patent application Ser. No.13/800,067, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM,now U.S. Patent Application Publication No. 2014/0263552 is incorporatedby reference in its entirety. U.S. Pat. No. 9,345,481, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, is also hereby incorporated byreference in its entirety.

Still referring to FIG. 3, the chassis 150 has at least one, andpreferably two, tapered attachment portions 152 formed thereon that areadapted to be received within corresponding dovetail slots 507 formedwithin a distal end of the frame 506. Each dovetail slot 507 may betapered or, stated another way, be somewhat V-shaped to seatinglyreceive the tapered attachment portions 152 therein. As can be furtherseen in FIG. 3, a shaft attachment lug 172 is formed on the proximal endof the firing shaft 170. When the interchangeable surgical tool assembly100 is coupled to the handle assembly 500, the shaft attachment lug 172is received in a firing shaft attachment cradle 542 formed in the distalend of the longitudinally movable drive member 540. The interchangeablesurgical tool assembly 100 also employs a latch system 180 forreleasably latching the shaft assembly 100 to the frame 506 of thehandle assembly 500. In at least one form, for example, the latch system180 includes a lock member or lock yoke 182 that is movably coupled tothe chassis 150. The lock yoke 182 includes two proximally protrudinglock lugs 184 that are configured for releasable engagement withcorresponding lock detents or grooves 509 in the distal attachmentflange of the frame 506. In various forms, the lock yoke 182 is biasedin the proximal direction by spring or biasing member. Actuation of thelock yoke 182 may be accomplished by a latch button 186 that is slidablymounted on a latch actuator assembly that is mounted to the chassis 150.The latch button 186 may be biased in a proximal direction relative tothe lock yoke 182. As will be discussed in further detail below, thelock yoke 182 may be moved to an unlocked position by biasing the latchbutton 186 the in distal direction DD which also causes the lock yoke182 to pivot out of retaining engagement with the distal attachmentflange of the frame 506. When the lock yoke 182 is in “retainingengagement” with the distal attachment flange of the frame 506, the locklugs 184 are retainingly seated within the corresponding lock detents orgrooves 509 in the distal end of the frame 506. Further detailsconcerning the latching system may be found in U.S. Patent ApplicationPublication No. 2014/0263541.

Attachment of the interchangeable surgical tool assembly 100 to thehandle assembly 500 will now be described with reference to FIG. 3. Tocommence the coupling process, the clinician may position the chassis150 of the interchangeable surgical tool assembly 100 above or adjacentto the distal end of the frame 506 such that the tapered attachmentportions 152 formed on the chassis 150 are aligned with the dovetailslots 507 in the frame 506. The clinician may then move the surgicaltool assembly 100 along an installation axis IA that is perpendicular tothe shaft axis SA to seat the tapered attachment portions 152 in“operable engagement” with the corresponding dovetail receiving slots507 in the distal end of the frame 506. In doing so, the shaftattachment lug 172 on the firing shaft 170 will also be seated in thecradle 542 in the longitudinally movable drive member 540 and theportions of pin 516 on the closure link 514 will be seated in thecorresponding hooks 162 in the closure shuttle 160. As used herein, theterm “operable engagement” in the context of two components means thatthe two components are sufficiently engaged with each other so that uponapplication of an actuation motion thereto, the components may carry outtheir intended action, function and/or procedure.

Returning now to FIG. 1, the surgical system 10 illustrated in thatFigure includes four interchangeable surgical tool assemblies 100, 200,300 and 1000 that may each be effectively employed with the same handleassembly 500 to perform different surgical procedures. The constructionof an exemplary form of interchangeable surgical tool assembly 100 wasbriefly discussed above and is discussed in further detail in U.S.Patent Application Publication No. 2014/0263541. Various detailsregarding interchangeable surgical tool assemblies 200 and 300 may befound in the various U.S. Patent Applications that were filed on evendate herewith and which have been incorporated by reference herein.Various details regarding interchangeable surgical tool assembly 1000will be discussed in further detail below.

As illustrated in FIG. 1, each of the surgical tool assemblies 100, 200,300 and 1000 includes a pair of jaws wherein at least one of the jaws ismovable between open positions wherein tissue may be captured ormanipulated between the two jaws and closed positions wherein the tissueis firmly retained therebetween. The movable jaw or jaws are movedbetween open and closed positions upon application of closure andopening motions applied thereto from the handle assembly or the roboticor automated surgical system to which the surgical tool assembly isoperably coupled. In addition, each of the illustrated interchangeablesurgical tool assemblies includes a firing member that is configured tocut tissue and fire staples from a staple cartridge that is supported inone of the jaws in response to firing motions applied thereto by thehandle assembly or robotic system. Each surgical tool assembly may beuniquely designed to perform a specific procedure, for example, to cutand fasten a particular type of and thickness of tissue within a certainarea in the body. The closing, firing and articulation control systemsin the handle assembly 500 or robotic system may be configured togenerate axial control motions and/or rotary control motions dependingupon the type of closing, firing and articulation system configurationsthat are employed in the surgical tool assembly. In one arrangement,when a closure control system in the handle assembly or robotic systemis fully actuated, one of the closure system control components whichmay, for example, comprise a closure tube assembly as described above,moves axially from an unactuated position to its fully actuatedposition. The axial distance that the closure tube assembly movesbetween its unactuated position to its fully actuated position may bereferred to herein as its “closure stroke length”. Similarly, when afiring system in the handle assembly or robotic system is fullyactuated, one of the firing system control components which may, forexample, comprise the longitudinally movable drive member as describedabove moves axially from its unactuated position to its fully actuatedor fired position. The axial distance that the longitudinally movabledrive member moves between its unactuated position and its fully firedposition may be referred to herein as its “firing stroke length”. Forthose surgical tool assemblies that employ articulatable end effectorarrangements, the handle assembly or robotic system may employarticulation control components that move axially through an“articulation drive stroke length”. In many circumstances, the closurestroke length, the firing stroke length and the articulation drivestroke length are fixed for a particular handle assembly or roboticsystem. Thus, each of the surgical tool assemblies must be able toaccommodate control movements of the closure, firing and/or articulationcomponents through each of their entire stroke lengths without placingundue stress on the surgical tool components which might lead to damageor catastrophic failure of surgical tool assembly.

Turning now to FIGS. 4-10, the interchangeable surgical tool assembly1000 includes a surgical end effector 1100 that comprises an elongatechannel 1102 that is configured to operably support a staple cartridge1110 therein. The end effector 1100 may further include an anvil 1130that is pivotally supported relative to the elongate channel 1102. Theinterchangeable surgical tool assembly 1000 may further include anarticulation joint 1200 and an articulation lock 1210 (FIGS. 5 and 8-10)which can be configured to releasably hold the end effector 1100 in adesired articulated position relative to a shaft axis SA. Detailsregarding the construction and operation of the articulation lock 1210may be found in in U.S. patent application Ser. No. 13/803,086, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, nowU.S. Patent Application Publication No. 2014/0263541, the entiredisclosure of which is hereby incorporated by reference herein.Additional details concerning the articulation lock may also be found inU.S. patent application Ser. No. 15/019,196, filed Feb. 9, 2016,entitled SURGICAL INSTRUMENT ARTICULATION MECHANISM WITH SLOTTEDSECONDARY CONSTRAINT, the entire disclosure of which is herebyincorporated by reference herein. As can be seen in FIG. 7, theinterchangeable surgical tool assembly 1000 can further include aproximal housing or nozzle 1300 comprised of nozzle portions 1302, 1304as well as an actuator wheel portion 1306 that is configured to becoupled to the assembled nozzle portions 1302, 1304 by snaps, lugs,screws etc. The interchangeable surgical tool assembly 1000 can furtherinclude a closure tube assembly 1400 which can be utilized to closeand/or open the anvil 1130 of the end effector 1100 as will be discussedin further detail below. Primarily referring now to FIGS. 8 and 9, theinterchangeable surgical tool assembly 1000 can include a spine assembly1500 which can be configured to support the articulation lock 1210. Inthe illustrated arrangement, the spine assembly 1500 comprises an“elastic” spine or frame member 1510 which will be described in furtherdetail below. A distal end portion 1522 of the elastic spine member 1510is attached to a distal frame segment 1560 that operably supports thearticulation lock 1210 therein. As can be seen in FIGS. 7 and 8, thespine assembly 1500 is configured to, one, slidably support a firingmember assembly 1600 therein and, two, slidably support the closure tubeassembly 1400 which extends around the spine assembly 1500. The spineassembly 1500 can also be configured to slidably support a proximalarticulation driver 1700.

As can be seen in FIG. 10, the distal frame segment 1560 is pivotallycoupled to the elongate channel 1102 by an end effector mountingassembly 1230. In one arrangement, for example, the distal end 1562 ofthe distal frame segment 1560 has a pivot pin 1564 formed thereon. Thepivot pin 1564 is adapted to be pivotally received within a pivot hole1234 formed in pivot base portion 1232 of the end effector mountingassembly 1230. The end effector mounting assembly 1230 is attached tothe proximal end 1103 of the elongate channel 1102 by a spring pin 1105or other suitable member. The pivot pin 1564 defines an articulationaxis B-B that is transverse to the shaft axis SA. See FIG. 4. Sucharrangement facilitates pivotal travel (i.e., articulation) of the endeffector 1100 about the articulation axis B-B relative to the spineassembly 1500.

Still referring to FIG. 10, in the illustrated embodiment, thearticulation driver 1700 has a distal end 1702 that is configured tooperably engage the articulation lock 1210. The articulation lock 1210includes an articulation frame 1212 that is adapted to operably engage adrive pin 1238 on the pivot base portion 1232 of the end effectormounting assembly 1230. In addition, a cross-link 1237 may be linked tothe drive pin 1238 and articulation frame 1212 to assist articulation ofthe end effector 1100. As indicated above, further details regarding theoperation of the articulation lock 1210 and the articulation frame 1212may be found in U.S. patent application Ser. No. 13/803,086, now U.S.Patent Application Publication No. 2014/0263541. Further detailsregarding the end effector mounting assembly and crosslink may be foundin U.S. patent application Ser. No. 15/019,245, filed Feb. 9, 2016,entitled SURGICAL INSTRUMENTS WITH CLOSURE STROKE REDUCTIONARRANGEMENTS, the entire disclosure of which is hereby incorporated byreference herein. In various circumstances, the elastic spine member1510 includes a proximal end 1514 which is rotatably supported in achassis 1800. In one arrangement, for example, the proximal end 1514 ofthe elastic spine member 1510 has a thread 1516 formed thereon forthreaded attachment to a spine bearing (not shown) that is configured tobe supported within the chassis 1800. Such an arrangement facilitatesrotatable attachment of the elastic spine member 1510 to the chassis1800 such that the spine assembly 1500 may be selectively rotated abouta shaft axis SA relative to the chassis 1800.

Referring primarily to FIG. 7, the interchangeable surgical toolassembly 1000 includes a closure shuttle 1420 that is slidably supportedwithin the chassis 1800 such that it may be axially moved relativethereto. In one form, the closure shuttle 1420 includes a pair ofproximally-protruding hooks 1421 that are configured for attachment tothe attachment pin 516 that is attached to the closure linkage assembly514 of the handle assembly 500 as was discussed above. A proximal end1412 of a proximal closure tube segment 1410 is coupled to the closureshuttle 1420 for relative rotation thereto. For example, a U-shapedconnector 1424 is inserted into an annular slot 1414 in the proximal end1412 of the proximal closure tube segment 1410 and is retained withinvertical slots 1422 in the closure shuttle 1420. See FIG. 7. Sucharrangement serves to attach the proximal closure tube segment 1410 tothe closure shuttle 1420 for axial travel therewith while enabling theclosure tube assembly 1400 to rotate relative to the closure shuttle1420 about the shaft axis SA. A closure spring (not shown) is journaledon the proximal end 1412 of the proximal closure tube segment 1410 andserves to bias the closure tube assembly 1400 in the proximal directionPD which can serve to pivot the closure trigger 512 on the handleassembly 500 (FIG. 3) into the unactuated position when theinterchangeable surgical tool assembly 1000 is operably coupled to thehandle assembly 500.

As indicated above, the illustrated interchangeable surgical toolassembly 1000 includes an articulation joint 1200. Other interchangeablesurgical tool assemblies, however, may not be capable of articulation.As can be seen in FIG. 10, upper and lower tangs 1415, 1416 protrudedistally from a distal end of the proximal closure tube segment 1410 tobe movably coupled to an end effector closure sleeve or distal closuretube segment 1430 of the closure tube assembly 1400. As can be seen inFIG. 10, the distal closure tube segment 1430 includes upper and lowertangs 1434, 1436 that protrude proximally from a proximal end thereof.An upper double pivot link 1220 includes proximal and distal pins thatengage corresponding holes in the upper tangs 1415, 1434 of the proximalclosure tube segment 1410 and distal closure tube segment 1430,respectively. Similarly, a lower double pivot link 1222 includesproximal and distal pins that engage corresponding holes in the lowertangs 1416 and 1436 of the proximal closure tube segment 1410 and distalclosure tube segment 1430, respectively. As will be discussed in furtherdetail below, distal and proximal axial translation of the closure tubeassembly 1400 will result in the closing and opening of the anvil 1130relative to the elongate channel 1102.

As mentioned above, the interchangeable surgical tool assembly 1000further includes a firing member assembly 1600 that is supported foraxial travel within the spine assembly 1500. In the illustratedembodiment, the firing member assembly 1600 includes an intermediatefiring shaft portion 1602 that is configured for attachment to a distalcutting portion or knife bar 1610. The firing member assembly 1600 mayalso be referred to herein as a “second shaft” and/or a “second shaftassembly”. As can be seen in FIGS. 7-10, the intermediate firing shaftportion 1602 may include a longitudinal slot 1604 in the distal endthereof which can be configured to receive a tab (not shown) on theproximal end of the knife bar 1610. The longitudinal slot 1604 and theproximal end of the knife bar 1610 can be sized and configured to permitrelative movement therebetween and can comprise a slip joint 1612. Theslip joint 1612 can permit the intermediate firing shaft portion 1602 ofthe firing member assembly 1600 to be moved to articulate the endeffector 1100 without moving, or at least substantially moving, theknife bar 1610. Once the end effector 1100 has been suitably oriented,the intermediate firing shaft portion 1602 can be advanced distallyuntil a proximal sidewall of the longitudinal slot 1604 comes intocontact with the tab on the knife bar 1610 to advance the knife bar 1610and fire the staple cartridge 1110 positioned within the elongatechannel 1102. As can be further seen in FIGS. 8 and 9, the elastic spinemember 1520 has an elongate opening or window 1525 therein to facilitateassembly and insertion of the intermediate firing shaft portion 1602into the elastic spine member 1520. Once the intermediate firing shaftportion 1602 has been inserted therein, a top frame segment 1527 may beengaged with the elastic spine member 1520 to enclose the intermediatefiring shaft portion 1602 and knife bar 1610 therein. Furtherdescription of the operation of the firing member assembly 1600 may befound in U.S. patent application Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541.

Further to the above, the interchangeable tool assembly 1000 can includea clutch assembly 1620 which can be configured to selectively andreleasably couple the articulation driver 1800 to the firing memberassembly 1600. In one form, the clutch assembly 1620 includes a lockcollar, or sleeve 1622, positioned around the firing member assembly1600 wherein the lock sleeve 1622 can be rotated between an engagedposition in which the lock sleeve 1622 couples the articulation driver1700 to the firing member assembly 1600 and a disengaged position inwhich the articulation driver 1700 is not operably coupled to the firingmember assembly 1600. When lock sleeve 1622 is in its engaged position,distal movement of the firing member assembly 1600 can move thearticulation driver 1700 distally and, correspondingly, proximalmovement of the firing member assembly 1600 can move the articulationdriver 1700 proximally. When lock sleeve 1622 is in its disengagedposition, movement of the firing member assembly 1600 is not transmittedto the articulation driver 1700 and, as a result, the firing memberassembly 1600 can move independently of the articulation driver 1700. Invarious circumstances, the articulation driver 1700 can be held inposition by the articulation lock 1210 when the articulation driver 1700is not being moved in the proximal or distal directions by the firingmember assembly 1600.

Referring primarily to FIG. 7, the lock sleeve 1622 can comprise acylindrical, or an at least substantially cylindrical, body including alongitudinal aperture 1624 defined therein configured to receive thefiring member assembly 1600. The lock sleeve 1622 can comprisediametrically-opposed, inwardly-facing lock protrusions 1626, 1628 andan outwardly-facing lock member 1629. The lock protrusions 1626, 1628can be configured to be selectively engaged with the intermediate firingshaft portion 1602 of the firing member assembly 1600. Moreparticularly, when the lock sleeve 1622 is in its engaged position, thelock protrusions 1626, 1628 are positioned within a drive notch 1605defined in the intermediate firing shaft portion 1602 such that a distalpushing force and/or a proximal pulling force can be transmitted fromthe firing member assembly 1600 to the lock sleeve 1622. When the locksleeve 1622 is in its engaged position, the second lock member 1629 isreceived within a drive notch 1704 defined in the articulation driver1700 such that the distal pushing force and/or the proximal pullingforce applied to the lock sleeve 1622 can be transmitted to thearticulation driver 1700. In effect, the firing member assembly 1600,the lock sleeve 1622, and the articulation driver 1700 will movetogether when the lock sleeve 1622 is in its engaged position. On theother hand, when the lock sleeve 1622 is in its disengaged position, thelock protrusions 1626, 1628 may not be positioned within the drive notch1605 of the intermediate firing shaft portion 1602 of the firing memberassembly 1600 and, as a result, a distal pushing force and/or a proximalpulling force may not be transmitted from the firing member assembly1600 to the lock sleeve 1622. Correspondingly, the distal pushing forceand/or the proximal pulling force may not be transmitted to thearticulation driver 1700. In such circumstances, the firing memberassembly 1600 can be slid proximally and/or distally relative to thelock sleeve 1622 and the proximal articulation driver 1700. Theclutching assembly 1620 further includes a switch drum 1630 thatinterfaces with the lock sleeve 1622. Further details concerning theoperation of the switch drum and lock sleeve 1622 may be found in U.S.patent application Ser. No. 13/803,086, now U.S. Patent ApplicationPublication No. 2014/0263541, and Ser. No. 15/019,196. The switch drum1630 can further comprise at least partially circumferential openings1632, 1634 defined therein which can receive circumferential mounts 1305that extend from the nozzle halves 1302, 1304 and permit relativerotation, but not translation, between the switch drum 1630 and theproximal nozzle 1300. See FIG. 6. Rotation of the nozzle 1300 to a pointwhere the mounts reach the end of their respective slots 1632, 1634 inthe switch drum 1630 will result in rotation of the switch drum 1630about the shaft axis SA. Rotation of the switch drum 1630 may ultimatelyresult in the movement of the lock sleeve 1622 between its engaged anddisengaged positions. In alternative embodiments, the nozzle 1300 may beemployed to operably engage and disengage the articulation drive systemwith the firing drive system. As indicated above, clutch assembly 1620may operate in the various manners described in further detail in U.S.patent application Ser. No. 13/803,086, now U.S. Patent ApplicationPublication No. 2014/0263541, and U.S. patent application Ser. No.15/019,196, which have each been herein incorporated by reference intheir respective entirety.

In the illustrated arrangement, the switch drum 1630 includes a anL-shaped slot 1636 that extends into a distal opening 1637 in the switchdrum 1630. The distal opening 1637 receives a transverse pin 1639 of ashifter plate 1638. In one example, the shifter plate 1638 is receivedwithin a longitudinal slot (not shown) that is provided in the locksleeve 1622 to facilitate axial movement of the lock sleeve 1622 whenengaged with the articulation driver 1700. Further details regarding theoperation of the shifter plate and shift drum arrangements may be foundin U.S. patent application Ser. No. 14/868,718, filed Sep. 28, 2015,entitled SURGICAL STAPLING INSTRUMENT WITH SHAFT RELEASE, POWERED FIRINGAND POWERED ARTICULATION, the entire disclosure of which is herebyincorporated by reference herein.

As also illustrated in FIGS. 7 and 8, the interchangeable tool assembly1000 can comprise a slip ring assembly 1640 which can be configured toconduct electrical power to and/or from the end effector 1100 and/orcommunicate signals to and/or from the end effector 1100, back to amicroprocessor in the handle assembly or robotic system controller, forexample. Further details concerning the slip ring assembly 1640 andassociated connectors may be found in U.S. patent application Ser. No.13/803,086, now U.S. Patent Application Publication No. 2014/0263541,and U.S. patent application Ser. No. 15/019,196 which have each beenherein incorporated by reference in their respective entirety as well asin U.S. patent application Ser. No. 13/800,067, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, now U.S. Patent ApplicationPublication No. 2014/0263552, which is hereby incorporated by referenceherein in its entirety. As also described in further detail in theaforementioned patent applications that have been incorporated byreference herein, the interchangeable surgical tool assembly 1000 canalso comprise at least one sensor that is configured to detect theposition of the switch drum 1630.

Referring again to FIG. 7, the chassis 1800 includes at least one, andpreferably two, tapered attachment portions 1802 formed thereon that areadapted to be received within corresponding dovetail slots 507 formedwithin the distal end portion of the frame 506 of the handle assembly500 as was discussed above. As can be further seen in FIG. 7, a shaftattachment lug 1605 is formed on the proximal end of the intermediatefiring shaft 1602. As will be discussed in further detail below, whenthe interchangeable surgical tool assembly 1000 is coupled to the handleassembly 500, the shaft attachment lug 1605 is received in a firingshaft attachment cradle 542 that is formed in the distal end of thelongitudinal drive member 540. See FIG. 3.

Various interchangeable surgical tool assemblies employ a latch system1810 for removably coupling the interchangeable surgical tool assembly1000 to the frame 506 of the handle assembly 500. As can be seen in FIG.7, for example, in at least one form, the latch system 1810 includes alock member or lock yoke 1812 that is movably coupled to the chassis1800. In the illustrated embodiment, for example, the lock yoke 1812 hasa U-shape with two spaced downwardly extending legs 1814. The legs 1814each have a pivot lug (not shown) formed thereon that are adapted to bereceived in corresponding holes 1816 formed in the chassis 1800. Sucharrangement facilitates pivotal attachment of the lock yoke 1812 to thechassis 1800. The lock yoke 1812 may include two proximally protrudinglock lugs 1818 that are configured for releasable engagement withcorresponding lock detents or grooves 509 in the distal end of the frame506 of the handle assembly 500. See FIG. 3. In various forms, the lockyoke 1812 is biased in the proximal direction by a spring or biasingmember 1819. Actuation of the lock yoke 1812 may be accomplished by alatch button 1820 that is slidably mounted on a latch actuator assembly1822 that is mounted to the chassis 1800. The latch button 1820 may bebiased in a proximal direction relative to the lock yoke 1812. The lockyoke 1812 may be moved to an unlocked position by biasing the latchbutton 1820 the in distal direction which also causes the lock yoke 1812to pivot out of retaining engagement with the distal end of the frame506. When the lock yoke 1812 is in “retaining engagement” with thedistal end of the frame 506, the lock lugs 1818 are retainingly seatedwithin the corresponding lock detents or grooves 509 in the distal endof the frame 506.

In the illustrated arrangement, the lock yoke 1812 includes at least oneand preferably two lock hooks 1824 that are adapted to contactcorresponding lock lug portions 1426 that are formed on the closureshuttle 1420. When the closure shuttle 1420 is in an unactuatedposition, the lock yoke 1812 may be pivoted in a distal direction tounlock the interchangeable surgical tool assembly 1000 from the handleassembly 500. When in that position, the lock hooks 1824 do not contactthe lock lug portions 1426 on the closure shuttle 1420. However, whenthe closure shuttle 1420 is moved to an actuated position, the lock yoke1812 is prevented from being pivoted to an unlocked position. Statedanother way, if the clinician were to attempt to pivot the lock yoke1812 to an unlocked position or, for example, the lock yoke 1812 was inadvertently bumped or contacted in a manner that might otherwise causeit to pivot distally, the lock hooks 1824 on the lock yoke 1812 willcontact the lock lugs 1426 on the closure shuttle 1420 and preventmovement of the lock yoke 1812 to an unlocked position.

Still referring to FIG. 10, the knife bar 1610 may comprise a laminatedbeam structure that includes at least two beam layers. Such beam layersmay comprise, for example, stainless steel bands that are interconnectedby, for example, welding or pinning together at their proximal endsand/or at other locations along their length. In alternativeembodiments, the distal ends of the bands are not connected together toallow the laminates or bands to splay relative to each other when theend effector is articulated. Such arrangement permits the knife bar 1610to be sufficiently flexible to accommodate articulation of the endeffector. Various laminated knife bar arrangements are disclosed in U.S.patent application Ser. No. 15/019,245. As can also be seen in FIG. 10,a middle support member 1614 is employed to provide lateral support tothe knife bar 1610 as it flexes to accommodate articulation of thesurgical end effector 1100. Further details concerning the middlesupport member and alternative knife bar support arrangements aredisclosed in U.S. patent application Ser. No. 15/019,245. As can also beseen in FIG. 10, a firing member or knife member 1620 is attached to thedistal end of the knife bar 1610.

FIG. 11 illustrates one form of a firing member 1660 that may beemployed with the interchangeable tool assembly 1000. In one exemplaryform, the firing member 1660 comprises a body portion 1662 that includesa proximally extending connector member 1663 that is configured to bereceived in a correspondingly shaped connector opening 1614 in thedistal end of the knife bar 1610. See FIG. 10. The connector 1663 may beretained within the connector opening 1614 by friction and/or welding orsuitable adhesive, etc. The body portion 1662 protrudes through anelongate slot 1104 in the elongate channel 1102 and terminates in a footmember 1664 that extends laterally on each side of the body portion1662. As the firing member 1660 is driven distally through the surgicalstaple cartridge 1110, the foot member 1664 rides within a passage 1105in the elongate channel 1102 that is located under the surgical staplecartridge 1110. As can be seen in FIG. 11, one form of the firing member1660 may further include laterally protruding central tabs, pins orretainer features 1680. As the firing member 1660 is driven distallythrough the surgical staple cartridge 1110, the central retainerfeatures 1680 ride on the inner surface 1106 of the elongate channel1102. The body portion 1662 of the firing member 1660 further includes atissue cutting edge or feature 1666 that is disposed between a distallyprotruding hook feature 1665 and a distally protruding top nose portion1670. As can be further seen in FIG. 11, the firing member 1660 mayfurther include two laterally extending top tabs, pins or anvilengagement features 1665. As the firing member 1660 is driven distally,a top portion of the body 1662 extends through a centrally disposedanvil slot 1138 and the top anvil engagement features 1672 ride oncorresponding ledges 1136 formed on each side of the anvil slot 1134.See FIGS. 13 and 14.

Returning to FIG. 10, the firing member 1660 is configured to operablyinterface with a sled assembly 1120 that is operably supported withinthe body 1111 of the surgical staple cartridge 1110. The sled assembly1120 is slidably displaceable within the surgical staple cartridge body1111 from a proximal starting position adjacent the proximal end 1112 ofthe cartridge body 1111 to an ending position adjacent a distal end 1113of the cartridge body 1111. The cartridge body 1111 operably supportstherein a plurality of staple drivers (not shown) that are aligned inrows on each side of a centrally disposed slot 1114. The centrallydisposed slot 1114 enables the firing member 1660 to pass therethroughand cut the tissue that is clamped between the anvil 1130 and the staplecartridge 1110. The drivers are associated with corresponding pockets1116 that open through the upper deck surface 1115 of the cartridgebody. Each of the staple drivers supports one or more surgical staple orfastener (not shown) thereon. The sled assembly 1120 includes aplurality of sloped or wedge-shaped cams 1122 wherein each cam 1122corresponds to a particular line of fasteners or drivers located on aside of the slot 1114. In the illustrated example, one cam 1122 isaligned with one line of “double” drivers that each support two staplesor fasteners thereon and another cam 1122 is aligned with another lineof “single” drivers on the same side of the slot 1114 that each operablysupport a single surgical staple or fastener thereon. Thus, in theillustrated example, when the surgical staple cartridge 1110 is “fired”,there will be three lines of staples on each lateral side of the tissuecut line. However, other cartridge and driver configurations could alsobe employed to fire other staple/fastener arrangements. The sledassembly 1120 has a central body portion 1124 that is configured to beengaged by the hook portion 1665 of the firing member 1660. Thus, whenthe firing member 1660 is fired or driven distally, the firing member1660 drives the sled assembly 1120 distally as well. As the firingmember 1660 moves distally through the cartridge 1110, the tissuecutting feature 1666 cuts the tissue that is clamped between the anvilassembly 1130 and the cartridge 1110 and the sled assembly 1120 drivesthe drivers upwardly in the cartridge which drive the correspondingstaples or fasteners into forming contact with the anvil assembly 1130.

In those embodiments wherein the firing member includes a tissue cuttingsurface, it may be desirable for the elongate shaft assembly to beconfigured in such a way so as to prevent the inadvertent advancement ofthe firing member unless an unspent staple cartridge is properlysupported in the elongate channel 1102 of the surgical end effector1100. If, for example, no staple cartridge is present at all and thefiring member is distally advanced through the end effector, the tissuewould be severed, but not stapled. Similarly, if a spent staplecartridge (i.e., a staple cartridge wherein at least some of the stapleshave already been fired therefrom) is present in the end effector andthe firing member is advanced, the tissue would be severed, but may notbe completely stapled, if at all. It will be appreciated that suchoccurrences could lead to undesirable catastrophic results during thesurgical procedure. U.S. Pat. No. 6,988,649 entitled SURGICAL STAPLINGINSTRUMENT HAVING A SPENT CARTRIDGE LOCKOUT, U.S. Pat. No. 7,044,352entitled SURGICAL STAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISMFOR PREVENTION OF FIRING, and U.S. Pat. No. 7,380,695 entitled SURGICALSTAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION OFFIRING, and U.S. patent application Ser. No. 14/742,933, entitledSURGICAL STAPLING INSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTINGFIRING SYSTEM ACTUATION WHEN A CARTRIDGE IS SPENT OR MISSING eachdisclose various firing member lockout arrangements. Each of thosereferences is hereby incorporated by reference in its entirety herein.

An “unfired”, “unspent”, “fresh” or “new” cartridge 1110 means hereinthat the cartridge 1110 has all of its fasteners in their“ready-to-be-fired positions”. When in that position, the sled assembly1120 is located in its starting position. The new cartridge 1110 isseated within the elongate channel 1102 and may be retained therein bysnap features on the cartridge body that are configured to retaininglyengage corresponding portions of the elongate channel 1102. FIGS. 15 and18 illustrate a portion of the surgical end effector 1100 with a new orunfired surgical staple cartridge 1110 seated therein. As can be seen inthose Figures, the sled assembly 1120 is in the starting position. Toprevent the firing system from being activated and, more precisely, toprevent the firing member 1660 from being distally driven through theend effector 1110 unless an unfired or new surgical staple cartridge hasbeen properly seated within the elongate channel 1102, the illustratedinterchangeable surgical tool assembly 1000 employs a firing memberlockout system generally designated as 1650.

Referring now to FIGS. 10 and 15-19, in one form, the firing memberlockout system 1650 includes movable lock member 1652 that is configuredto retainingly engage the firing member 1660 when a surgical staplecartridge 1110 is not properly seated within the elongate channel 1102.The lock member 1652 comprises at least one laterally moving lockingportion 1654 that is configured to retainingly engage a correspondingportion of the firing member when the sled assembly 1120 is not presentwithin the cartridge 1110 in its starting position. In the illustratedarrangement, the lock member 1652 employs two laterally moving lockingportions 1654 wherein each locking portion 1654 engages a laterallyextending portion of the firing member 1660.

In the illustrated embodiment, the lock member 1652 comprises agenerally U-shaped spring member wherein each laterally movable leg orlocking portion 1654 extends from a central spring portion 1653 and isconfigured to move in lateral directions represented by “L” in FIGS. 18and 19. It will be appreciated that the term “lateral directions” refersto directions that are transverse to the shaft axis SA. The spring orlock member 1652 may be fabricated from high strength spring steel orsimilar material. The central spring portion 1653 may be seated within aslot 1236 in the end effector mounting assembly 1230. See FIG. 10. Ascan be seen in FIGS. 15-17, each of the laterally movable legs orlocking portions 1654 has a distal end 1656 with a locking window 1658therein. When the locking member 1652 is in a locked position, thecentral retainer feature 1680 on each lateral side extends into thecorresponding locking window 1658 to retainingly prevent the firingmember from being distally axially advanced.

Operation of the firing member lock out system will be explained withreference to FIGS. 15-19. FIGS. 15 and 18 illustrate a portion of thesurgical end effector 1100 with a new unfired cartridge 1110 properlyinstalled therein. As can be seen in those Figures, the sled assembly1120 includes an unlocking feature 1126 that corresponds to each of thelaterally movable locking portion 1654. In the illustrated arrangement,an unlocking feature 1126 is provided on or extends proximally from eachof the central wedge-shaped cams 1122. In alternative arrangements, theunlocking feature 1126 may comprise a proximally protruding portion ofthe corresponding wedge-shaped cam 1122. As can be seen in FIG. 18, whenthe sled assembly 1120 is in its starting position, the unlockingfeatures 1124 engage and bias the corresponding locking portions 1654laterally in a direction that is transverse to the shaft axis SA. Whenthe locking portions 1654 are in those unlocked orientations, thecentral retainer features 1680 are not in retaining engagement withtheir corresponding locking window 1658. When in those orientations, thefiring member 1660 may be distally axially advanced (fired). However,when a cartridge is not present in the elongate channel 1102 or the sledassembly has been moved out of its starting position (meaning thecartridge is partially or completely fired), the locking portions 1654spring laterally into retaining engagement with the firing member 1660.When in that position as illustrated in FIG. 19, the firing member 1660cannot be moved distally.

FIGS. 16 and 17 illustrate the retraction of the firing member 1660 backto the starting position after firing the cartridge 1110 and driving thesled assembly 1120 distally. FIG. 16 depicts the initial reengagement ofthe retaining feature 1680 into its corresponding locking window 1658.FIG. 17 illustrates the retaining feature in its locked position whenthe firing member 1660 has been fully retracted back to its startingposition. To assist in the lateral displacement of the locking portions1654 when they are each initially contacted by the proximally movingretaining features 1680, each of the retaining features 1680 may beprovided with a proximally facing, laterally tapered end portion. Suchlockout system prevents actuation of the firing member 1660 when a newunfired cartridge is not present or when a new unfired cartridge ispresent, but has not been properly seated in the elongate channel 1102.In addition, the lockout system may prevent the clinician from distallyadvancing the firing member in the case where a spent or partially firedcartridge has been inadvertently properly seated within the elongatechannel. Another advantage that may be provided by the lockout system1650 is that, unlike other firing member lock out arrangements thatrequire movement of the firing member into and out of alignment with thecorresponding slots/passages in the staple cartridge, the firing member1660 remains in alignment with the cartridge passages while in thelocked and unlocked position. The locking portions 1654 are designed tomove laterally into and out of engagement with corresponding sides ofthe firing member. Such lateral movement of the locking portions orportion is distinguishable from other locking arrangements that move invertical directions to engage and disengage portions of the firingmember.

Returning to FIGS. 13 and 14, in one form, the anvil 1130 includes anelongated anvil body portion 1132 and a proximal anvil mounting portion1150. The elongated anvil body portion 1132 includes an outer surface1134 that defines two downwardly extending tissue stop members 1136 thatare adjacent to the proximal anvil mounting portion 1150. The elongatedanvil body portion 1132 also includes an underside 1135 that defines anelongate anvil slot 1138. In the illustrated arrangement shown in FIG.14, the anvil slot 1138 is centrally disposed in the underside 1135. Theunderside 1135 includes three rows 1140, 1141, 1142 of staple formingpockets 1143, 1144 and 1145 located on each side of the anvil slot 1138.Adjacent each side of the anvil slot 1138 are two elongate anvilpassages 1146. Each passage 1146 has a proximal ramp portion 1148. SeeFIG. 13. As the firing member 1660 is advanced distally, the top anvilengagement features 1632 initially enter the corresponding proximal rampportions 1148 and into the corresponding elongate anvil passages 1146.

Turning to FIGS. 12 and 13, the anvil slot 1138, as well as the proximalramp portion 1148, extend into the anvil mounting portion 1150. Statedanother way, the anvil slot 1138 divides or bifurcates the anvilmounting portion 1150 into two anvil attachment flanges 1151. The anvilattachments flanges 1151 are coupled together at their proximal ends bya connection bridge 1153. The connection bridge 1153 serves to providesupport to the anvil attachment flanges 1151 and can serve to make theanvil mounting portion 1150 more rigid than the mounting portions ofother anvil arrangements wherein the anvil attachment flanges are notconnected at their proximal ends. As can also be seen in FIGS. 12 and14, the anvil slot 1138 has a wide portion 1139 to accommodate the topportion and top anvil engagement features 1632 of the firing member1660.

As can be seen in FIGS. 13 and 20-24, each of the anvil attachmentflanges 1151 includes a transverse mounting hole 1156 that is configuredto receive a pivot pin 1158 (FIGS. 10 and 20) therethrough. The anvilmounting portion 1150 is pivotally pinned to the proximal end 1103 ofthe elongate channel 1102 by the pivot pin 1158 which extends throughmounting holes 1107 in the proximal end 1103 of the elongate channel1102 and the mounting hole 1156 in anvil mounting portion 1150. Sucharrangement serves to pivotally affix the anvil 1130 to the elongatechannel 1102 for selective pivotal travel about a fixed anvil axis A-Awhich is transverse to the shaft axis SA. See FIG. 5. The anvil mountingportion 1150 also includes a cam surface 1152 that extends from acentralized firing member parking area 1154 to the outer surface 1134 ofthe anvil body portion 1132.

In the illustrated arrangement, the anvil 1130 is moved between an openposition and closed positions by axially advancing and retracting thedistal closure tube segment 1430. As will be discussed in further detailbelow, a distal end portion of the distal closure tube segment 1430 hasan internal cam surface formed thereon that is configured to camminglyengage the cam surface 1552 or cam surfaces formed on the anvil mountingportion 1150. FIG. 22 illustrates a cam surface 1152 a formed on theanvil mounting portion 1150 so as to establish a single contact path1155 a with the internal cam surface 1444, for example, on the distalclosure tube segment 1430. FIG. 23 illustrates a cam surface 1152 b thatis configured relative to the internal cam surface 1444 on the distalclosure tube segment to establish two separate and distinct arcuatecontact paths 1155 b between the cam surface 1152 on the anvil mountingportion 1150 and internal cam surface 1444 on the distal closure tubesegment 1430. In addition to other potential advantages discussedherein, such arrangement may serve to better distribute the closureforces from the distal closure tube segment 1430 to the anvil 1130. FIG.24 illustrates a cam surface 1152 c that is configured relative to theinternal cam surface 1444 of the distal closure tube segment 1430 toestablish three distinct zones of contact 1155 c and 1155 d between thecam surfaces on the anvil mounting portion 1150 and the distal closuretube segment 1430. The zones 1155 c, 1155 d establish larger areas ofcamming contact between the cam surface or cam surfaces on the distalclosure tube segment 1430 and the anvil mounting portion 1150 and mayserve to better distribute the closure forces to the anvil 1130.

As the distal closure tube segment 1430 cammingly engages the anvilmounting portion 1150 of the anvil 1130, the anvil 1130 is pivoted aboutthe anvil axis AA which results in the pivotal movement of the distalend of the end 1133 of elongate anvil body portion 1132 toward thesurgical staple cartridge 1110 and distal end 1105 of the elongatechannel 1102. As the anvil body portion 1132 begins to pivot, itcontacts the tissue that is to be cut and stapled which is nowpositioned between the underside 1135 of the elongate anvil body portion1132 and the deck 1116 of the surgical staple cartridge 1110. As theanvil body portion 1132 is compressed onto the tissue, the anvil 1130may experience considerable amounts of resistive forces. These resistiveforces are overcome as the distal closure tube 1430 continues its distaladvancement. However, depending upon their magnitudes and points ofapplication to the anvil body portion 1132, these resistive forces couldtend to cause portions of the anvil 1130 to flex which may generally beundesirable. For example, such flexure may cause misalignment betweenthe firing member 1660 and the passages 1148, 1146 within the anvil1130. In instances wherein the flexure is excessive, such flexure couldsignificantly increase the amount of firing force required to fire theinstrument (i.e., drive the firing member 1660 through the tissue fromits starting to ending position). Such excessive firing force may resultin damage to the end effector, and/or the firing member, and/or theknife bar, and/or the firing drive system components, etc. Thus, it maybe advantageous for the anvil to be constructed so as to resist suchflexure.

FIGS. 25-27 illustrate an alternative anvil embodiment that includesfeatures that may improve the stiffness of the anvil body and itsresistance to flexure forces that may be generated during the closingand/or firing processes. The anvil 1130′ may otherwise be identical inconstruction to the anvil 1130 described above except for thedifferences discussed herein. As can be seen in those Figures, the anvil1130′ has an elongate anvil body 1132′ that has an upper body portion1165 that has an anvil cap 1170 attached thereto. In the embodimentdepicted in FIGS. 25-27, the anvil cap 1170 is roughly rectangular inshape and has an outer cap perimeter 1172. The perimeter 1172 of theanvil cap 1170 is configured to be inserted through thecorrespondingly-shaped opening 1137 formed in the upper body portion1165 and received on axially extending internal ledge portions 1139formed therein. See FIG. 27. The internal ledge portions 1139 areconfigured to support the corresponding long sides 1177 of the anvil cap1170. In an alternative embodiment, the anvil cap 1170 may be slide ontothe internal ledges 1139 through an opening (not shown) in the distalend 1133 of the anvil body 1132′. In yet another embodiment, no internalledge portions are provided. The anvil body 1132′ and the anvil cap 1170may be fabricated from suitable metal that is conducive to welding. Afirst weld 1178 may extend around the entire cap perimeter 1172 of theanvil cap 1170 or it may only be located along the long sides 1177 ofthe anvil cap 1170 and not the distal end 1173 and/or proximal end 1175thereof. The first weld 1178 may be continuous or it may bediscontinuous or intermittent. In those embodiments where the first weld1178 is discontinuous or intermittent, the weld segments may be equallydistributed along the long sides 1177 of the anvil cap 1170 or the weldsegments may be more densely spaced closer to the distal ends of thelong sides 1177 or more densely spaced closer to the proximal ends ofthe long sides 1177. In still other arrangements, the weld segments maybe more densely spaced in the center areas of the long sides 1177 of theanvil cap 1170.

FIGS. 28-30 illustrate an anvil cap 1170′ that is configured to be“mechanically interlocked” to the anvil body 1132′ as well as welded tothe upper body portion 1165. In this embodiment, a plurality ofretention formations 1182 are formed into the wall 1180 of the upperbody portion 1165 that defines opening 1137. As used in this context,the term “mechanically interlocked” means that the anvil cap will remainaffixed to the elongate anvil body regardless of the orientation of theelongate anvil body and without any additional retaining or fasteningsuch as welding and/or adhesive, for example. The retention formations1182 may protrude inwardly into the opening 1137 from the opening wall1180. The retention formations 1182 may be integrally formed into thewall 1180 or otherwise be attached thereto. The retention formations1182 are designed to frictionally engage a corresponding portion of theanvil cap 1170′ when it is installed in the opening 1137 to frictionallyretain the anvil cap 1170′ therein. In the illustrated embodiment, theretention formations 1182 protrude inwardly into the opening 1137 andare configured to be frictionally received within a correspondinglyshaped engagement area 1184 formed in the outer perimeter 1172′ of theanvil cap 1170′. In the illustrated arrangement, the retentionformations 1182 only correspond to the long sides 1177′ of the anvil cap1170′ and are not provided in the portions of the wall 1180 thatcorrespond to the distal end 1173 or proximal end 1175 of the anvil cap1170′. In alternative arrangements, the retention formations 1182 mayalso be provided in the portions of the wall 1180 that correspond to thedistal end 1173 and proximal end 1175 of the anvil cap 1170′ as wall asthe long sides 1177′ thereof. In still other arrangements, the retentionformations 1182 may only be provided in the portions of the wall 1180that correspond to one or both of the distal and proximal ends 1173,1175 of the anvil cap 1170′. In still other arrangements, the retentionformations 1182 may be provided in the portions of the wall 1180corresponding to the long sides 1177′ and only one of the proximal anddistal ends 1173, 1175 of the anvil cap 1170′. It will be furtherunderstood that the retention protrusions in all of the foregoingembodiments may be alternatively formed on the anvil cap with theengagement areas being formed in the elongate anvil body.

In the embodiment illustrated in FIGS. 28-30, the retention formations1182 are equally spaced or equally distributed along the wall portions1180 that correspond to the long sides 1177′ of the anvil cap 1170′. Inalternative embodiments, the retention formations 1182 may be moredensely spaced closer to the distal ends of the long sides 1177′ or moredensely spaced closer to the proximal ends of the long sides 1177′.Stated another way, the spacing between those retention formationsadjacent the distal end, the proximal end or both the distal andproximal ends may be less than the spacing of the formations located inthe central portion of the anvil cap 1170′. In still other arrangements,the retention formations 1182 may be more densely spaced in the centerareas of the long sides 1177′ of the anvil cap 1170′. Also inalternative embodiments, the correspondingly shaped engagement areas1184 may not be provided in the outer perimeter 1172′ or in portions ofthe outer perimeter 1172′ of the anvil cap 1170′. In other embodiments,the retention formations and correspondingly shaped engagement areas maybe provided with different shapes and sizes. In alternativearrangements, the retention formations may be sized relative to theengagement areas so that there is no interference fit therebetween. Insuch arrangements, the anvil cap may be retained in position by welding,adhesive, etc.

In the illustrated example, a weld 1178′ may extend around the entireperimeter 1172′ of the anvil cap 1170′ or the weld 1178′ may only belocated along the long sides 1177′ of the anvil cap 1170′ and not thedistal end 1173 and/or proximal end 1175 thereof. The weld 1178′ may becontinuous or it may be discontinuous or intermittent. In thoseembodiments where the weld 1178′ is discontinuous or intermittent, theweld segments may be equally distributed along the long sides 1177′ ofthe anvil cap 1170′ or the weld segments may be more densely spacedcloser to the distal ends of the long sides 1177′ or more densely spacedcloser to the proximal ends of the long sides 1177′. In still otherarrangements, the weld segments may be more densely spaced in the centerareas of the long sides 1177′ of the anvil cap 1170′.

FIGS. 31 and 32 illustrate another anvil arrangement 1130″ that is hasan anvil cap 1170″ attached thereto. In the depicted example, the anvilcap 1170″ is roughly rectangular in shape and has an outer cap perimeter1172″. The outer cap perimeter 1172″ is configured to be insertedthrough the correspondingly-shaped opening 1137″ in upper body portion1165 of the anvil body 1132″ and received on axially extending internalledge portions 1139″ and 1190″ formed therein. See FIG. 32. The ledgeportions 1139″ and 1190″ are configured to support the correspondinglong sides 1177″ of the anvil cap 1170″. In an alternative embodiment,the anvil cap 1170″ may be slid onto the internal ledges 1139″ and 1190″through an opening (not shown) in the distal end 1133″ of the anvil body1132′. The anvil body 1132″ and the anvil cap 1170″ may be fabricatedfrom metal material that is conducive to welding. A first weld 1178″ mayextend around the entire perimeter 1172″ of the anvil cap 1170″ or itmay only be located along the long sides 1177″ of the anvil cap 1170″and not the distal end 1173″ and/or proximal end (not shown) thereof.The weld 1178″ may be continuous or it may be discontinuous orintermittent. It will be appreciated that the continuous weld embodimenthas more weld surface area due to the irregularly shape perimeter of theanvil cap 1170″ as compared to the embodiments with a straight perimetersides such as the anvil caps shown in FIG. 26, for example. In thoseembodiments where the weld 1178″ is discontinuous or intermittent, theweld segments may be equally distributed along the long sides 1177″ ofthe anvil cap 1170″ or the weld segments may be more densely spacedcloser to the distal ends of the long sides 1177″ or more densely spacedcloser to the proximal ends of the long sides 1177″. In still otherarrangements, the weld segments may be more densely spaced in the centerareas of the long sides 1177″ of the anvil cap 1170″.

Still referring to FIGS. 31 and 32, the anvil cap 1170″ may beadditionally welded to the anvil body 1132″ by a plurality of seconddiscrete “deep” welds 1192″. For example, each weld 1192″ may be placedat the bottom of a corresponding hole or opening 1194″ provided throughthe anvil cap 1170″ so that a discrete weld 1192″ may be formed alongthe portion of the anvil body 1132″ between the ledges 1190″ and 1139″.See FIG. 32. The welds 1192″ may be equally distributed along the longsides 1177″ of the anvil cap 1170″ or the welds 1192″ may be moredensely spaced closer to the distal ends of the long sides 1177″ or moredensely spaced closer to the proximal ends of the long sides 1177″. Instill other arrangements, the welds 1192″ may be more densely spaced inthe center areas of the long sides 1177″ of the anvil cap 1170″.

FIG. 33 illustrates another anvil cap 1170′″ that is configured to bemechanically interlocked to the anvil body 1132′″ as well as welded tothe upper body portion 1165. In this embodiment, a “tongue-in-groove”arrangement is employed along each long side 1177′″ of the anvil cap1170′″. In particular, a laterally extending continuous or intermittenttab 1195′″ protrudes from each of the long sides 1177′″ of the anvil cap1170′″. Each tab 1195″ corresponds to an axial slot 1197′″ formed in theanvil body 1132′″. The anvil cap 1170′″ is slid in from an opening (notshown) in the distal end of the anvil body 1132′″ to “mechanically”affix the anvil cap to the anvil body 1132′″. The tabs 1195′″ and slots1197′″ may be sized relative to each other to establish a slidingfrictional fit therebetween. In addition, the anvil cap 1170′″ may bewelded to the anvil body 1132′″. The anvil body 1132′″ and the anvil cap1170′″ may be fabricated from metal that is conducive to welding. Theweld 1178′″ may extend around the entire perimeter 1172′″ of the anvilcap 1170′″ or it may only be located along the long sides 1177′″ of theanvil cap 1170′″. The weld 1178′″ may be continuous or it may bediscontinuous or intermittent. In those embodiments where the weld1178′″ is discontinuous or intermittent, the weld segments may beequally distributed along the long sides 1177′″ of the anvil cap 1170′″or the weld segments may be more densely spaced closer to the distalends of the long sides 1177′″ or more densely spaced closer to theproximal ends of the long sides 1177′″. In still other arrangements, theweld segments may be more densely spaced in the center areas of the longsides 1177′″ of the anvil cap 1170′″.

The anvil embodiments described herein with anvil caps may provideseveral advantages. One advantage for example, may make the anvil andfiring member assembly process easier. That is, the firing member may beinstalled through the opening in the anvil body while the anvil isattached to the elongate channel. Another advantage is that the uppercap may improve the anvil's stiffness and resistance to theabove-mentioned flexure forces that may be experienced when clampingtissue. By resisting such flexure, the frictional forces normallyencountered by the firing member 1660 may be reduced. Thus, the amountof firing force required to drive the firing member from its starting toending position in the surgical staple cartridge may also be reduced.

As indicated above, as the anvil 1130 begins to pivot, the anvil body1132 contacts the tissue that is to be cut and stapled which ispositioned between the undersurface of the elongate anvil body 1132 andthe deck of the surgical staple cartridge 1110. As the anvil body 1132is compressed onto the tissue, the anvil 1130 may experienceconsiderable amounts of resistive forces. To continue the closureprocess, these resistive forces must be overcome by the distal closuretube segment 1430 as it cammingly contacts the anvil mounting portion1150. These resistive forces may be generally applied to the distalclosure tube segment 1430 in the vertical directions V which, ifexcessive, could conceivably cause the distal closure tube segment 1430to expand or elongate in the vertical direction (distance ID in FIG. 31may increase). If the distal closure tube 1430 elongates in the verticaldirections, the distal closure tube segment 1430 may not be able toeffectively close the anvil 1130 and retain the anvil 1130 in the fullyclosed position. If that condition occurs, the firing member 1660 mayencounter dramatically higher resistance which will then require higherfiring forces to distally advance the firing member.

FIGS. 34 and 35 illustrate one form of a closure member for applying aclosure motion to a movable jaw of a surgical instrument. In theillustrated arrangement, the closure member comprises, for example, adistal closure tube segment 1430 that has a closure body portion 1470.As discussed above, one form of the interchangeable surgical toolassembly 1000 is configured so as to facilitate selective articulationof the surgical end effector 1100. To facilitate such articulation, thedistal closure tube segment 1430 is movably coupled to the proximalclosure tube segment 1410 by means of an upper tang 1434 and a lowertang 1436 and upper and lower double pivot links 1220 and 1222. See FIG.10. In one arrangement, the distal closure tube segment 1430 may bemachined or otherwise formed from round bar stock manufactured from, forexample, suitable metal material. In the illustrated arrangement, theclosure body 1470 has an outer surface 1431 and an inner surface 1433that defines an upper wall portion 1440 that has an upper wallcross-sectional thickness UWT and a lower wall portion 1442 that has alower wall thickness LWT. The upper wall portion 1440 is located abovethe shaft axis SA and the lower wall portion 1442 is located below theshaft axis SA. The distal end 1441 of the upper wall portion 1440 has aninternal cam surface 1444 formed thereon at a cam angle θ. Also in theillustrated embodiment, UWT>LWT which serves to provide a longerinternal cam surface 1444 than might other wise be attainable if thedistal closure tube segment has a uniform wall thickness. A longinternal cam surface may be advantageous for transferring the closureforces to the cam surface(s) on the anvil mounting portion 1150. As canalso be seen in FIGS. 34 and 35, the transitional sidewalls 1446, 1448that are located on each side of the shaft axis SA between the upperwall portion 1440 and the lower wall portion 1442 comprise generallyflat, vertically extending internal sidewall surfaces 1451, 1453 thatmay be generally parallel to each other. The transitional sidewalls1446, 1448 each have a wall thickness that transitions from the upperwall thickness to the lower wall thickness.

In the illustrated arrangement, the distal closure tube segment 1430also includes positive jaw or anvil opening features 1462 thatcorrespond to each of the sidewalls 1446 and 1448 and protrude inwardlytherefrom. As can be seen in FIGS. 34 and 35, the anvil opening features1462 are formed on a lateral mounting body 1460 that sized to bereceived within a correspondingly-shaped cavity 1447, 1449 machined orotherwise formed in the transitional sidewalls 1446, 1448 adjacent thedistal end 1438 of the distal closure tube segment 1430. The positiveanvil opening features 1462 extend inwardly through correspondingopenings 1450, 1452 in the transitional sidewalls 1446, 1448. In theillustrated arrangement, the lateral mounting bodies 1460 are welded tothe distal closure tube segment 1430 with welds 1454. In addition to thewelds or in alternative to the welds, the lateral mounting bodies 1460may be retained in place with a mechanical/frictional fit,tongue-in-groove arrangements, adhesive, etc.

FIGS. 36-41 illustrate one example of the use of the distal closure tubesegment 1430 to move the anvil 1130 from a fully closed position to afully open position. FIGS. 36 and 39 illustrate the position of thedistal closure tube segment 1430 and, more particularly the position ofone of the positive anvil opening features 1462 when the distal closuretube segment 1430 is in the fully closed position. In the illustratedexample, an anvil opening ramp 1162 is formed on the underside of eachof the anvil attachment flanges 1151. When the anvil 1130 and the distalclosure tube segment 1430 are in their fully closed positions shown inFIG. 36, each of the positive anvil opening features 1462 is located ina cavity 1164 that is established between the anvil opening ramps 1162and the bottom portion of the elongate channel 1102. When in thatposition, the positive anvil opening features 1462 do not contact theanvil mounting portion 1150 or at least do not apply any significantopening motions or forces thereto. FIGS. 37 and 40 illustrate thepositions of the anvil 1130 and the distal closure tube segment 1430upon the initial application of an opening motion in the proximaldirection PD to the distal closure tube segment 1430. As can be seen inFIG. 37, the positive jaw opening features 1462 have initially contactedthe anvil opening ramps 1164 to cause the anvil 1130 to start pivotingto an open position. In the illustrated arrangement, each of thepositive anvil opening features 1462 has a ramped or rounded distal end1463 to facilitate better camming contact with the corresponding anvilopening ramp 1162. In FIGS. 38 and 41, the distal closure tube segment1430 has been retracted back to its fully retracted position which hascaused the positive anvil opening features 1462 to be driven to thedistal ends of the anvil opening ramps 1162 which causes the anvil 1130to be pivoted to its fully open position as shown therein. Otherembodiments may not employ the positive jaw opening features, but mayrely on springs or other biasing arrangements to bias the anvil to theopen position when the distal closure tube segment has been retracted toits proximal-most starting position.

FIGS. 42 and 43 illustrate another closure member for applying closuremotions to a movable jaw of a surgical instrument. In this example, theclosure member comprises a distal closure tube segment 1430′ that may besimilar to the distal closure tube segment 1430 without the positiveanvil opening features. The distal closure tube segment 1430′ has aclosure body 1470′ that has an outer surface 1440′ and an inner surface1433′ that define an upper wall portion 1440′ and a lower wall portion1442′. As indicated above, it may be desirable to employ as large ofinternal camming surface 1444′ as possible in order to maximize thecamming contact with the camming surface on the anvil mounting portion1150 to thereby effectively transfer the closure forces thereto. Thus,the upper wall portion 1440′ of the distal closure tube segment 1430′may be provided with the thickest wall thickness UWT and the lowerportion of the distal closure tube segment 1430′ may have the thinnestwall thickness LWT. For reference purposes, the UWT and LWT are measuredalong a common reference line that extends through a center axis orpoint C of the distal closure tube segment 1430′. Thus, where UWT isdiametrically opposite from LWT, UWT>LWT. Such wall thicknessarrangements facilitate formation of a longer internal camming surface1444′.

As can be seen in FIG. 43, the distal closure tube segment 1430′ has anouter surface 1431′ that has circular cross-sectional shape. The distalclosure tube segment 1430′ may be machined from solid bar stock. In theillustrated example, internal radius R₁ from a first center axis A.extends to the inner surface 1433′ and the outer radius R₂ from a secondcenter axis A_(outer) extends to the outer surface 1431′. In theillustrated example, axis A_(inner) is offset by distance OR from axisA_(outer) and R₂>R₁.

FIG. 44 illustrates another closure member for applying closure motionsto a movable jaw of a surgical instrument. In this example, the closuremember comprises a distal closure tube segment 1430″ that has a closurebody 1470″. The closure body 1470″ has an outer surface 1431′ and aninner surface 1433″ that define an upper wall portion 1440″ that has anupper wall thickness UWT and a lower wall portion 1442″ that has a lowerwall thickness LWT and two sidewall portions 1435′ that each has asidewall thickness SWT. In the illustrated example, UWT>LWT. Inaddition, SWT>UWT. Thus, SWT>UWT>LWT. In the illustrated arrangement,sidewall portions 1435′ have the same sidewall thickness SWT. In otherarrangements, the sidewall portions 1435′ may have differentthicknesses. As can be seen in FIG. 44, each sidewall portion 1435′defines an internal, vertically extending internal surface portion1437′. In the illustrated embodiment, the vertically extending internalsurface portions are approximately parallel to each other. Such thickervertical sidewall portions 1435′ may help to prevent or at leastminimize the vertical elongation of the distal closure tube segment1430″ when in use.

In the example depicted in FIG. 45, R₁ and R₂ are measured from a commoncenter point or center axis C and R₁>R₂. Each of the sidewall portions1435″ of the closure body portion 1470′″ of the distal closure tubesegment 1430′″ that extend between the upper portion 1431″ and 1433″have a sidewall thickness SWT that is approximately equal to the UWT atpoints along a horizontal reference line HR. The horizontal referenceline HR is perpendicular to a vertical reference line VR that extendsthrough the center axis C and along which the UWT and LWT may bemeasured and compared. Thus, SWT=UWT. In other examples, SWT, whenmeasured along the horizontal reference line HR may be slightly lessthan the UWT. The SWT may continue to decrease until the side wallportions 1435′ transition into the lower portion 1433′ that has aconstant lower wall thickness LWT. Thus, the inner sidewalls 1437″extend at an angle A₂ when measured from a corresponding verticalreference axis VR′ that is perpendicular to the horizontal referenceaxis HR and parallel to vertical reference axis VR.

FIG. 46 illustrates another closure member for applying closure motionsto a movable jaw of a surgical instrument. In this example, the closuremember comprises a distal closure tube segment 1430″ that has a closurebody 1470″ that has a round outer surface 1431″ and a rectangular shapedinternal passage 1439 extending therethrough. The outer surface 1431″ islocated a distance R from the geometric center point or center axis C.When measured along a vertical reference axis VR that extends throughthe center point or center axis C as shown, the upper wall thickness UWTis equal to the lower wall thickness LWT. When measure along ahorizontal reference axis HR that extends through the center point orcenter axis C and which is perpendicular to the vertical reference axisVR, the thicknesses SWT of the sidewall portions 1437″ are greater thanthe upper wall and lower wall thicknesses UWT and LWT. Thus, SWT isgreater than UWT and LWT. Stated another way, the portion of the distalclosure tube segment 1430″ located above the horizontal reference lineHR is a mirror image of the portion of the distal closure tube segment1430″ located below the horizontal reference line HR. In this example,the side portions 1437″ are thicker than the upper and lower wallportions and may tend to prevent or minimize the tendency of the distalclosure tube segment to elongate in the vertical directions. Theinternal camming surface may be formed on the distal end of the upperwall portion 1440″.

In the illustrated arrangement, the anvil 1130 is moved between open andclosed positions by distally advancing the distal closure tube segment1430. As can be seen in FIG. 41, when the anvil 1130 is in the fullyopen position, the distal ends 1163 of the anvil attachment flanges 1151may extend above the deck surface 1116 of the staple cartridge 1110.When the closure process is commenced by distally advancing the distalclosure tube segment in the distal direction DD, the distal ends 1163 ofthe anvil attachment flanges 1151 extend past the deck surface 1116 ofthe staple cartridge 1110 to thereby prevent infiltration of tissuetherebetween which might hamper the closure process. See FIG. 40. Oncethe anvil 1130 has been moved to the fully closed position by the distalclosure tube segment 1430, the distal ends 1461 of the lateral mountingbodies on the distal closure tube segment 1430 further act as tissuestops to prevent tissue from infiltrating therebetween. See FIG. 41.

FIG. 47 depicts portion of a surgical end effector 110′ that may besimilar to the surgical end effector 110 of the interchangeable surgicaltool assembly 100 of FIGS. 1 and 2. In the example illustrated in FIG.47, the anvil 114 includes an elongate body portion 190 and an anvilmounting portion 192. The anvil mounting portion 192 comprises twospaced anvil mounting flanges 194 that protrude proximally from theelongate body portion 190. Each anvil mounting flange 194 has anoutwardly extending trunnion 196 thereon. The trunnions 196 are eachmovably received within a corresponding kidney slot or elongated arcuatetrunnion slot 197 that is provided in the elongate channel 112. When theanvil 114 is in a “fully opened” position, the trunnions 196 aregenerally located in the bottom portions 198 of the elongated arcuatetrunnion slots 197. The anvil 114 can be moved to a closed position bydistally advancing the distal closure tube segment 142 in the distaldirection DD so that the end 148 of the distal closure tube segment 142rides up a cam surface 193 that is formed on the anvil mounting portion192 of the anvil 114. As the distal end 148 of the distal closure tubesegment 142 is distally advanced along a cam surface 193 on the anvilmounting portion 192, the distal closure tube segment 142 causes thebody portion 190 of the anvil 114 to pivot and move axially relative tothe surgical staple cartridge 116. When the distal closure tube segment142 reaches the end of its closure stroke, the distal end 148 of thedistal closure tube segment 142 abuts/contacts an abrupt anvil ledge 191and serves to position the anvil 114 so that the forming pockets (notshown) in the underside of the body portion 190 are properly alignedwith the staples in the cartridge. The anvil ledge 191 is definedbetween the cam surface 193 on the anvil mounting portion 192 and theelongate anvil body portion 190. Stated another way, in thisarrangement, the cam surface 193 does not extend to the outermostsurface 195 of the anvil body 190. After the distal closure tube 142 hasreached this fully extended position, any further application of closuremotions/forces to the anvil 114, may cause damage to the anvil and/orthe closure system components. As can be seen in FIG. 47, in thisarrangement, the closure force F_(H) is parallel to the shaft axis SA.The distance between an axis or plane T_(A) passing through the centersof the trunnions 196 to the closure force vector F_(H) is represented asdistance X_(R). This distance X_(R) times the closure force F_(H)represents a closure moment C_(M) that is applied to the anvil 114.

FIGS. 48 and 49 illustrate the closure force configurations for an anvil1130 of a surgical end effector 1100 of the interchangeable toolassembly 1000. As indicated above, the anvil trunnions 1158 arepivotally mounted within holes 1154 in the elongate channel 1102. Unlikethe anvil 114 described above, the anvil 1130 does not move axially.Instead, the anvil 1130 is constrained to only pivot about the anvilaxis AA. As the distal closure tube segment 1430 is advanced in thedistal direction DD under the horizontal closure force F_(H1), theinteraction between the internal cam surface 1444 on the distal closuretube segment 1430 and the cam surface 1152 on the anvil mounting portion1150 results in the distal closure tube segment 1430 experiencing avertical closure force component V_(F). The resultant force vector F_(N)experienced by the cam surface 1152 on the anvil mounting portion 1150is “normal to” or perpendicular to the internal cam surface 1444. AngleΘ in FIGS. 48 and 49 represents the angle of the camming surface 1152 asa well as the internal camming surface 1440 to the horizontal. Thedistance between this resultant force vector F_(N) and an axis or planeT_(A) that extends through the centers of the anvil trunnions 1158 isrepresented as moment arm M_(A). This moment arm distance M_(A) timesthe resultant force vector F_(N) represents a closure moment C_(M1) thatis applied to the anvil 1130. Thus, in applications wherein thehorizontal closure forces F_(H)=F_(H1), the actual amount of closuretorque applied to anvil 1130 will be greater than the amount of closuretorque applied to the anvil 114 because M_(A)>X_(R) and therefor theclosure moment applied to the anvil 1130 will be greater than theclosure moment applied to the anvil 114. FIG. 49 also illustrates theresistive forces established by the tissue during the closure process.F_(T) represents the force generated by the tissue when the tissue isclamped between the anvil and the staple cartridge. This “counter”moment M_(T) that is applied to the anvil 1130 equals the distance X_(T)between the tissue force T_(F) and the axis or plane T_(A) that extendsthrough the centers of the anvil trunnions 1158 times the tissue forceT_(F). Thus, in order to achieve a desired amount of anvil closure,C_(M1) must be greater than M_(T).

Returning to the example depicted in FIG. 47, it can be seen that thefiring bar 170 is attached to a firing member 174 that, when in astarting or unfired position, is located within the elongate channel 112and, more particularly, is located completely distal to the distalclosure tube segment 142 in a position wherein a top portion 175 of thefiring member 174 is in contact with a portion of the anvil 114. Becausethe firing member 174 is located in a position wherein the top portion175 thereof can contact the anvil as the anvil 114 is moved to theclosed position, such arrangement may result in the need for higherclosure forces to move the anvil 114 to a completely or fully closedposition. In addition, when the firing system is activated, higherfiring forces may be required to overcome the frictional interferencebetween the top portion 175 of the firing member 174 and the anvil 114.Conversely as can be seen in FIG. 48, in the end effector 1100, thefiring member 1660 is “parked” in the firing member parking area 1154that is within the distal closure tube segment 1430. When the firingmember 1660 is located within the firing member parking area 1154 withinthe distal closure tube segment 1430, it is unable to generatesignificant frictional forces with the anvil. Thus, one of theadvantages that may be achieved by parking the firing member 1660completely within the distal closure tube segment 1430 may be thereduction of the amount of closure force necessary to close the anvil toa fully closed position and/or a reduction in the amount of firing forceneeded to advance the firing member from the starting to ending positionwithin the end effector. Stated another way, parking the firing member1660 so that the firing member 1660 is completely proximal to the distalend of the distal closure tube segment 1430 and the internal cam surface1444 thereon and in a starting position wherein any frictional contactbetween the firing member and the anvil is eliminated or reduced, mayultimately require lower closure and firing forces to be generated foroperation of the end effector.

As discussed above, excessive flexure of the anvil during the closureand firing processes can lead to the need for undesirably higher firingforces. Thus, stiffer anvil arrangements are generally desirable.Returning to FIGS. 20 and 21, another advantage that may be provided bythe anvil 1130 and elongate channel 1102 depicted therein is that theanvil mounting portion 1150 of the anvil 1130 is generally more robustand therefor stiffer than other anvil and elongate channel arrangements.FIG. 50 illustrates use of stiffener gussets 199 between the anvilmounting flanges 194 and the elongate anvil body portion 190. Similargusset arrangements may also be employed between the anvil attachmentflanges 1151 and anvil body 1132 of anvil 1130 to further enhance anvilstiffness.

As indicated above, the interchangeable surgical tool 1000 includes anelastic spine member 1520. As can be seen in FIGS. 6, 7, 7A, 8 and51-54, the distal end portion 1522 of the elastic spine member 1520 isseparated from the proximal end portion 1524 of the elastic spine member15 by a stretch feature 1530 formed in the elastic spine member 1520. Inaddition, a stretch limiting insert 1540 is retainingly supportedbetween the distal end portion 1522 and the proximal end portion 1524.In various arrangements, the elastic spine member 1520 may be fabricatedfrom, for example, suitable polymeric material, rubber, etc. which has amodulus of elasticity designated as ME₁ for reference purposes. Thestretch feature 1530 may include a plurality of stretch cavities 1532.As can be seen in FIG. 7A, the illustrated stretch feature 1530 includesfour triangular-shaped stretch cavities 1532 that are arranged to definesome what flexible wall segments 1534 therebetween. Other shapes andnumbers of stretch cavities 1532 may be employed. The stretch cavities1532 may be molded or machined into the elastic spine member 1520, forexample.

Still referring to FIGS. 6, 7 and 51-54, the stretch limiting insert1540 comprises a body portion 1541 which has a modulus of elasticitydesignated as ME₂ for reference purposes. As can be seen in FIG. 6, thebody portion 1541 includes two downwardly extending mounting lugs 1542that are each configured to be seated into mounting cavities 1535 formedin the elastic spine member 1520. See also FIG. 7A. To provide thestretch limiting insert 1540 with a desired amount of stretch capacityand elasticity, the body portion 1541 in the illustrated arrangement isprovided with a plurality of upper cavities 1543. The illustratedexample includes four upper cavities 1543 that are relatively square orrectangular in shape and which are spaced to define flexible walls 1544therebetween. Other embodiments may include other numbers and shapes ofupper cavities. The body portion 1541 of the illustrated stretchlimiting insert 1540 also includes a centrally disposed, downwardlyprotruding central lug portion 1545 that is configured to be seated in acentral cavity 1536 above the stretch feature 1530. See FIG. 7A. In theillustrated example, the central lug portion 1545 includes a pair ofcentral passages 1546 that extend laterally therethrough to define aflexible wall 1547 therebetween.

Also in the illustrated example, the stretch limiting insert 1540includes an elongated lateral cavity 1548 that is positioned on eachlateral side of the body portion 1541. Only one lateral cavity 1548 maybe seen in FIGS. 6 and 51-54. Each elongated lateral cavity 1548 isconfigured to support a corresponding stretch limiter 1550 therein.Thus, in the described example, two stretch limiters 1550 are employedin the stretch limiting insert 1540. In at least one arrangement, thestretch limiter 1550 includes an elongate body portion 1552 thatterminates on each end with a downwardly extending mounting lug 1554.Each mounting lug 1554 is received in a corresponding lug cavity 1549formed in the body portion 1541. The stretch limiter may have a modulusof elasticity for reference purposes of ME₃. In at least onearrangement, ME₃<ME₂<ME₁.

Actuation of the interchangeable surgical tool assembly 1000 whenoperably attached to the handle assembly 500 will now be described infurther detail with reference to FIGS. 51-54. FIG. 51 illustrates theanvil 1130 in an open position. As can be seen in that Figure, thedistal closure tube segment 1430 is in its starting or unactuatedposition and the positive anvil opening features 1462 have pivoted theanvil 1130 to the open position. In addition, the firing member 1660 isin the unactuated or starting position wherein the upper portion,including the top nose portion 1630, is parked in the firing memberparking area 1154 of the anvil mounting portion 1150. When theinterchangeable tool assembly 1000 is in this unactuated state, thestretch limiting insert 1540 is in an unstretched state. The axiallength of the stretch limiting insert 1540 when in the unstretched stateis represented by L_(us) in FIG. 51. L_(us) represents the distancebetween a reference axis A that corresponds to the proximal end of thebody portion 1541 of the stretch limiting insert 1540 and a referenceaxis B that corresponds to the distal end of the body portion 1541 asshown in FIG. 51. The axis labeled F corresponds to the location of thedistal end of the staple cartridge 1110 that has been properly seatedwithin the elongate channel 1102. It will be understood that when thetool assembly 1000 is in this unactuated state, the elastic spine member1520 is in a relaxed unstretched state.

FIG. 52 illustrates the interchangeable surgical tool assembly 1000after the closure drive system 510 has been activated as described aboveto drive the distal closure tube segment 1430 distally in the distaldirection DD. As the distal closure tube segment 1430 moves distally,the cam surface 1444 on the distal end 1441 of the upper wall portion1440 of the distal closure tube segment 1430 cammingly contacts the camsurface 1152 on the anvil mounting portion 1150 and pivots the anvil1130 to the closed position as shown. The closure drive system 510 movesthe distal closure tube segment 1430 through its entire closure strokedistance and then is deactivated and the distal closure tube segment isaxially locked or otherwise retained in that position by the closuredrive system 510. As the distal closure tube segment 1430 contacts theanvil mounting portion 1150, the closure forces generated by the distaladvancement of the distal closure tube segment 1430 on the anvil 1130will also axially advance the anvil 1130 and the elongate channel 1102in the distal direction DD. The stretch feature 1530 in the elasticspine 1520 will begin to stretch to accommodate this distal advancementof the elongate channel 1102 and anvil 1130. Axis B as shown in FIG. 52is a reference axis for the stretch limiting insert 1540 when in arelaxed or unstretched state. Axis C corresponds to the end of thestretch limiting insert 1540 after the stretch limiting insert has beenstretched into its maximum elongated stated. The distance L_(s)represents the maximum amount or length that the stretch limiting insert1540 may elongate. Axis G corresponds to the location of the distal endof the surgical staple cartridge 1110 after the anvil 1130 has beenmoved to that “first” closed position. The distance L_(T) betweenreference axes F and G represents the axial distance that the elongatechannel 1102 and the anvil 1130 have traveled during actuation of theclosure drive system 510. This distance L_(T) may be equal to thedistance L_(S) that the stretch limiting insert 1540 was stretchedduring the closure process as limited by the stretch limiter 1550.

Returning to FIG. 51, it can be noted that there is a space S betweeneach mounting lug 1554 of the stretch limiter 1550 and the inner walls1551 of each of the lug cavities 1549 prior to commencement of theclosure process. As can be seen in FIG. 52 the spaces S are gone. Thatis, each of the mounting lugs 1554 abuts its corresponding cavity wall1549 in the stretch limiting insert 1540. Thus the stretch limiter 1550serves to limit the amount of elongation experienced by the stretchlimiting insert 1540 which in turn limits the amount of distal travel ofthe elongate channel 1102 and anvil 1130 relative to the proximal endportion 1524 of the elastic spine 1520. The distal closure tube 1430 isaxially locked in position by the closure drive system 510. When in thatposition, the anvil 1130 is retained in a ‘first” closed positionrelative to the surgical staple cartridge 1110. Because the firing drivesystem 530 has yet to be actuated, the firing member 1660 has not movedand remains parked in the firing member parking area 1154. The positionof the underside of the anvil 1130 when in the “first” closed positionis represented by axis K in FIGS. 52 and 53.

FIG. 53 illustrates the position of the firing member 1660 after thefiring drive system 530 has been initially actuated. As can be seen inthat Figure, the firing member 1660 has been distally advanced out ofthe firing member parking area 1154. The top portion of the firingmember 1660 and, more specifically, each of the top anvil engagementfeatures 1672 has entered the proximal ramp portion 1138 of thecorresponding axial passage 1146 in the anvil 1130. At this point in theprocess, the anvil 1130 may be under considerable bending stress causedby the tissue that is clamped between the underside of the anvil 1130and the deck of the staple cartridge 1110. This bending stress, as wellas the frictional resistance between the various portions of the firingmember and the anvil 1130 and elongate channel 1102, serve toessentially retain the elongate channel 1102 and the distal closure tubesegment in a static condition while the firing member 1660 is initiallydistally advanced. During this time period, the amount of force requiredto fire the firing member 1660 or, stated another way, the amount offorce required to distally push the firing member 1660 through thetissue that is clamped between the anvil 1130 and the cartridge 1110 isincreasing. See line 1480 in FIG. 55. Also during this time period, thestretch limiting insert is trying to retract the elongate channel 1102and anvil 1130 in the proximal direction PD into the distal closure tubesegment 1430. Once the amount of friction between the firing member 1660and the anvil 1130 and elongate channel 1102 is less than the retractionforce generated by the stretch limiting insert 1540, the stretchlimiting insert 1540 will cause the elongate channel 1102 and anvil 1130to be drawn proximally further into the distal closure tube segment1430. The position of the distal end 1113 of the staple cartridge 1110after the elongate channel 1102 and anvil 1130 have traveled in theproximal direction PD is represented as position H in FIG. 54. The axialdistance that the elongate channel 1102 and the anvil 1130 traveled inthe proximal direction PD is represented as distance I in FIG. 54. Thisproximal movement of the anvil 1130 and the elongate channel 1102 intothe distal closure tube segment 1430 will result in the application ofadditional closure forces to the anvil 1130 by the distal closure tubesegment 1430. Line M in FIG. 54 represents the “second” closed positionof the anvil 1130. The distance between position K and position M whichis represented as distance N comprises the vertical distance that thedistal end 1133 of the anvil body 1132 traveled between the first closedposition and the second closed position.

The application of additional closure forces to the anvil 1130 by thedistal closure tube segment 1430 when the anvil 1130 is in the secondclosed position, resists the amount of flexure forces applied to theanvil 1130 by the tissue that is clamped between the anvil 1130 and thecartridge 1110. Such condition may lead to better alignment between thepassages in the anvil body 1130 and the firing member 1660 which mayultimately reduce the amount of frictional resistance that the firingmember 1660 experiences as it continues to advance distally through theend effector 1100. Thus, the amount of firing force required to advancethe firing member through the balance of its firing stroke to the endingposition may be reduced. This reduction of the firing force can be seenin the chart in FIG. 55. The chart depicted in FIG. 55 compares thefiring force (Energy) required to fire the firing member from thebeginning to the end of the firing process. Line 1480 represents theamount of firing force required to move the firing member 1660 from itsstarting to ending position when the end effector 1100 is clampingtissue therein. Line 1482, for example, represents the amount of firingforce required to move the firing member the interchangeable surgicaltool assembly 1000 described above. Line 1482 represents the firingforce required to move the firing member 174 from its starting to endingposition through tissue that is clamped in the end effector 110 or 110′.As can be seen from that chart, the firing forces required by both ofthe surgical tool assemblies 100, 1000 are substantially the same orvery similar until the point in time 1484 wherein the elastic spineassembly 1510 of the interchangeable tool assembly 1000 results in anapplication of a second amount of closure force to the anvil. As can beseen in the chart of FIG. 55, when the second amount of closure force isexperienced by the anvil 1130 (point 1484), the amount of closure forcerequired to complete the firing process is less than the amount ofclosure force required to complete the closing process in tool assembly100.

FIG. 56 compares the amount of firing load required to move a firingmember of various surgical end effectors from a starting position (0.0)to an ending position (1.0). The vertical axis represents the amount offiring load and the horizontal axis represents the percentage distancethat the firing member traveled between the starting position (0.0) andthe ending position (1.0). Line 1490 depicts the firing force requiredto fire, for example, the firing member of a surgical tool assembly 100or similar tool assembly. Line 1492 depicts the firing force required tofire the firing member of a surgical tool assembly that employs thevarious firing member improvements and configurations that may bedisclosed in, for example, U.S. patent application Ser. No. 15/385,917,entitled STAPLE CARTRIDGE COMPRISING STAPLES WITH DIFFERENT CLAMPINGBREADTHS, and the other above-mentioned U.S. Patent Applications thatwere filed on even date herewith and which have been incorporated byreference herein in their respective entirety. Line 1494 depicts thefiring force required to fire the firing member from its starting toending position of surgical tool assemblies that employ at least some ofthe features and arrangements disclosed herein for stiffening the anvil.Line 1496 depicts the firing force required to fire, for example,surgical tool assemblies that employ the elastic spine arrangement andat least some of the features and arrangements disclosed herein forstiffening the anvil. As can be seen in that Figure, the surgical toolassembly that employs the elastic spine arrangement and at least some ofthe anvil stiffening arrangements disclosed herein have a much lowerforce-to-fire requirement.

Traditionally, surgical stapling and cutting instruments comprisedrobust mechanical lockouts configured to protect against unauthorizedfiring of the surgical stapling and cutting instruments because of thedangers associated with such unauthorized firing. For example, firing asurgical stapling and cutting instrument that is not loaded with astaple cartridge, or is loaded with a staple cartridge that has alreadybeen fired, may cause severe bleeding if the tissue cutting is performedwithout any tissue stapling.

The recent transition to motorized surgical stapling and cuttinginstruments presents new challenges in ensuring the safe operation ofsuch instruments. Among other things, the present disclosure presentsvarious electrical and electro-mechanical lockouts that are suitable foruse with motorized surgical stapling and cutting instruments. Sincelockout failure can result in a serious risk to the patient, the presentdisclosure presents multiple safeguards that operate in redundancy toensure that lockout failures are avoided. The present disclosureprovides various techniques for detecting when a staple cartridge isattached to an end effector of a surgical stapling and cuttinginstrument. The present disclosure further provides various techniquesfor detecting whether an attached staple cartridge is spent.

An end effector 4000 of a surgical stapling system is illustrated inFIG. 57. The end effector 4000 comprises a frame 4002, a cartridge jaw4004, and an anvil 4006. The cartridge jaw 4004 extends fixedly from theframe 4002. The anvil 4006 is movable between an open, or unclamped,position and a closed, or clamped, position (FIG. 57) relative to thecartridge jaw 4004. In alternative embodiments, the cartridge jaw 4004is movable between an open, or unclamped, position and a closed, orclamped, position relative to the anvil 4006. In at least one suchembodiment, the anvil 4006 extends fixedly from the frame 4002.

The cartridge jaw 4004 includes a channel or carrier 4022 configured toreceive a staple cartridge, such as a staple cartridge 4008, forexample. Referring to FIG. 58, the staple cartridge 4008 comprises acartridge body 4010. The cartridge body 4010 comprises a deck 4012configured to support the tissue of a patient, a longitudinal slot 4014,and six longitudinal rows of staple cavities 4016 defined therein. Eachstaple cavity 4016 is configured to receive and removably store a stapletherein. The staple cartridge 4008 further comprises staple driversconfigured to drive the staples out of the staple cavities 4016. Otherstaple cartridges with various other arrangements of staple cavities,decks, and/or staples are envisioned for use with the end effector 4000.

Further to the above, the staple cartridge 4008 further comprises a sled4018 configured to engage the staple drivers. More specifically, thesled 4018 comprises ramps 4020 configured to engage cams defined on thestaple drivers and lift the staple drivers and the staples within thestaple cavities 4016 as the sled 4018 is moved distally through thestaple cartridge 4008. A firing member is configured to motivate thesled 4018 distally from a proximal, unfired, or starting position towarda distal, fired, or end position during a staple firing stroke.

Referring to FIGS. 58, 59, 60B, the staple cartridge 4008 includes acartridge circuit 4024. The cartridge circuit 4024 includes a storagemedium 4026, a cartridge connector-region 4017 comprising a plurality ofexternal electrical contacts 4028, and a cartridge-status circuitportion 4032 that includes a trace element 4034. The storage medium 4026can be a memory that stores information about the staple cartridge 4008such as, for example, various characteristics of the staple cartridge4008 including a firing status, staple-type, staple-size, cartridgebatch number, and/or cartridge color.

Referring to FIGS. 61-62, the sled 4018 further includes a circuitbreaker 4019 comprising a gripping member 4021 that is configured tocapture and sever the trace element 4034 from the cartridge-statuscircuit portion 4032 as the sled 4018 is advanced distally from astarting position. By severing the trace element 4034, the circuitbreaker 4019 transitions the cartridge-status circuit portion 4032 froma closed configuration to an open configuration which signals atransition of the staple cartridge 4000 from an unfired, or unspent,status to a fired, or spent, status. Information about this transitioncan be stored in the storage medium 4026. Accordingly, sensing that astaple cartridge 4008 has a severed trace element 4034 can indicate thatthe staple cartridge 4008 has already been fired.

As illustrated in FIGS. 61-62, the gripping member 4021 of the circuitbreaker 4019 has a right-angle configuration with a first portion 4023protruding or extending away from a bottom surface 4025 of the sled 4018and a second portion 4027 defining a right angle with the first portion4023. The second portion 4027 is spaced apart from the bottom surface4025 a sufficient distance to snuggly hold a severed trace element 4034,as illustrated in FIG. 62. This arrangements ensures that the severedtrace element 4034 is not accidently lost in a patient's body aftercompletion of the firing steps of an end effector 4000. In at least oneinstance, the circuit breaker 4019 may comprise a magnetic memberconfigured to magnetically retain a severed trace element 4034, forexample. In various instances, a trace element can be cut or displacedto sever or establish an electrical connection indicative of whether astaple cartridge has been fired without completely severing the traceelement.

In at least one instance, a carrier 4022 may include a Hall effectsensor 4029 (FIG. 62A) configured to detect the presence of a magnetembedded into or attached to a sled 4018. While the sled 4018 is at astart, proximal, or unfired position, the Hall effect sensor 4029 isable to detect the presence of the magnet. But, once the sled 4018 isadvanced distally toward an end, distal, or fired position, the Halleffect sensor 4029 no longer senses the presence of the magnet. In atleast one instance, a controller 4050 can be configured to receive inputfrom the Hall effect sensor 4029 to assess the position of the sled 4018and, accordingly, determine whether an attached staple cartridge 4008 isspent based on the readings of the Hall effect sensor 4029. In certaininstances, the Hall effect sensor 4029 can be attached to the sled 4018while the corresponding magnet is attached to and/or embedded into thecarrier 4022. In certain instances, other position sensors can beemployed to determine whether the sled 4018 is at the start, proximal,or unfired position.

In certain instances, a Hall effect sensor and magnet combination can beemployed to determine whether a staple cartridge is spent by detectingwhether a staple driver is at a start or unfired position. As describedabove, during a firing stroke, a sled 4018 is transitioned from a start,proximal, or unfired position toward an end, distal, or fired positionto motivate a plurality of staple drivers to deploy staples of a staplecartridge. Each staple driver is generally lifted from a start orunfired position toward an final or fired position to deploy one or morestaples. The Hall effect sensor can be coupled to the carrier 4022 orthe staple cartridge 4008. The corresponding magnet can be coupled to astaple driver such as, for example, a proximal staple driver of thestaple cartridge 4008. In at least one instance, the correspondingmagnet is coupled to a proximal-most staple driver of the staplecartridge 4008. In certain instances, the Hall effect sensor is coupledto the carrier 4022 or the staple cartridge 4008 while the magnet iscoupled to the staple driver. In certain instances, the Hall effectsensor is coupled to the carrier 4022 or the staple cartridge 4008 whilethe magnet is coupled to the proximal-most staple driver.

The Hall effect sensor is configured to detect the presence of themagnet while the staple driver is in the start or unfired position. Butonce the sled 4018 motivates the staple driver to be lifted from thestart or unfired position, the Hall effect sensor no longer senses thepresence of the magnet. Alternatively, the Hall effect sensor and magnetarrangement can be configured to detect when the staple driver reachesthe final or fired position, for example. The Hall effect sensor andmagnet arrangement can be configured to detect when the distal-moststaple driver reaches the final or fired position, for example. In anyevent, a controller 4050 can be configured to receive input from theHall effect sensor to assess the position of the staple driver and,accordingly, determine whether an attached staple cartridge 4008 isspent based on the readings of the Hall effect sensor 4029. In certaininstances, other position sensors can be employed to determine whetherthe staple driver is at the start or unfired position.

As illustrated in FIG. 62A, the controller 4050 may comprise a processor4052 and/or one or more storage mediums such as, for example, a memory4054. By executing instruction code stored in the memory 4054, theprocessor 4052 may control various components of the surgical staplingand cutting instrument such as a firing system 4056 and a user interface4058 such as, for example, a display. The memory 4054 includes programinstructions which, when executed by the processor 4052, cause theprocessor 4052 to determine whether an attached staple cartridge 4008 isspent based on input from one or more sensors such as, for example, theHall effect sensor 4029.

The user interface 4058 may include one or more visual feedback elementsincluding display screens, backlights, and/or LEDs, for example. Incertain instances, the user interface 4058 may comprise one or moreaudio feedback systems such as speakers and/or buzzers, for example. Incertain instances, the user interface 4058 may comprise one or morehaptic feedback systems, for example. In certain instances, the userinterface 4058 may comprise combinations of visual, audio, and/or hapticfeedback systems, for example.

In at least one instance, the carrier 4022 includes one or moreelectrical contacts configured to be electrically connected tocorresponding electrical contacts in a sled 4018 of a staple cartridge4008 seated in the carrier 4022. The electrical contacts define anelectrical circuit 4031 (FIG. 62B) that remains closed while the sled4018 is in a proximal unfired position. The electrical circuit 4031 istransitioned into an open configuration when the sled 4018 is advancedtoward an end, distal, or fired position due to the severance of theelectrical connection between the electrical contacts of the carrier4022 and the sled 4018.

The electrical circuit 4031 may further include one or more sensors suchas, for example, voltage or current sensors configured to detect whetherthe electrical circuit 4031 is in a closed configuration or an openconfiguration. Input from the one or more sensors can be received by acontroller 4050. The controller 4050 can determine whether an attachedstaple cartridge 4008 is spent based on the input from the one or moresensors. The memory 4054 may include program instructions which, whenexecuted by the processor 4052, cause the processor 4052 to determinewhether an attached staple cartridge 4008 is spent based on input fromthe one or more sensors.

In certain instances, a staple cartridge 4008 may include an ETS lockoutwith a continuity path along a path of a sled defined by sled guiderails, for example. When the sled is in a proximal-most position, thesled is configured to interrupt the electrical path. However, when thesled is advanced distally the electrical path is completed and is sensedby an inductance sensor in the carrier 4022, for example. In variousinstances, one or more inductance sensors can be configured to track oneor more proximal forming pockets for identification of the finger printof staples received within the proximal pockets. The inductance sensorscan be configured to detect the absence of the staples from theirrespective forming pockets. Examples of ETS lockouts are described inU.S. Patent Application Publication No. 2013/0248577, entitled SURGICALSTAPLING DEVICE WITH LOCKOUT SYSTEM FOR PREVENTING ACTUATION IN THEABSENCE OF AN INSTALLED STAPLE CARTRIDGE, filed Mar. 26, 2012, now U.S.Pat. No. 9,078,653, the entire disclosure of which is incorporated byreference herein.

In at least one instance, a staple cartridge, similar to the staplecartridge 4008, includes at least one electrical circuit 4033 (FIG. 62C)that comprises two electrical contacts that are spaced apart from oneanother. The electrical contacts are configured to be bridged by astaple of the staple cartridge when the staple is in an unfiredposition. Accordingly, the electrical circuit 4033 is in a closedconfiguration when the staple is in the unfired position. In addition,the electrical circuit 4033 is in an open configuration when the stapleis lifted by a staple driver for deployment into tissue. The lifting ofthe staple by a staple driver during a firing stroke separates thestaple from the electrical contacts of the electrical circuit 4033thereby transitioning the electrical circuit 4033 into an openconfiguration.

The electrical circuit 4033 may further include one or more sensors suchas, for example, voltage or current sensors configured to detect whetherthe electrical circuit 4033 is in a closed configuration or an openconfiguration. Input from the one or more sensors can be received by acontroller 4050. The controller 4050 can determine whether an attachedstaple cartridge 4008 is spent based on the input from the one or moresensors. The memory 4054 may include program instructions which, whenexecuted by the processor 4052, cause the processor 4052 to determinewhether an attached staple cartridge 4008 is spent based on input fromthe one or more sensors.

In at least one instance, a staple cartridge, similar to the staplecartridge 4008, includes at least one electrical circuit 4035 (FIG. 62D)that comprises a conductive bridge that is configured to be rupturedwhen a staple driver of the staple cartridge is lifted to deploy one ormore staples into tissue, which causes the electrical circuit 4035 to betransitioned from a closed configuration to an open configuration. Thelifting of the staple driver during a firing stroke causes theconductive bridge of the electrical circuit 4035 to be severed, cut, ordisplaced thereby transitioning the electrical circuit 4033 into an openconfiguration. The conductive bridge of the electrical circuit 4035 isplaced in a predetermined path of the staple driver. In at least oneinstance, the conductive bridge extends across, or at least partiallyacross, a staple pocket configured to store the staple in an unfiredposition.

The electrical circuit 4035 may further include one or more sensors suchas, for example, voltage or current sensors configured to detect whetherthe electrical circuit 4035 is in a closed configuration or an openconfiguration. Input from the one or more sensors can be received by acontroller 4050. The controller 4050 can determine whether an attachedstaple cartridge 4008 is spent based on the input from the one or moresensors. The memory 4054 may include program instructions which, whenexecuted by the processor 4052, cause the processor 4052 to determinewhether an attached staple cartridge 4008 is spent based on input fromthe one or more sensors.

In various instances, upon determining that an attached staple cartridge4008 is spent, a controller 4050 is configured to cause the firingsystem 4056 to be deactivated and/or provide user feedback as to thereason for the deactivation through a user interface such as, forexample, a display 4058. The controller 4050 may identify and/or aid auser in addressing the cause of the deactivation of the firing system4056. For example, the controller 4050 may alert a user that an attachedstaple cartridge is spent or is not the correct type to be used with theend effector 4000. Other techniques for determining whether a staplecartridge is spent are included in U.S. patent application Ser. No.15/131,963, entitled METHOD FOR OPERATING A SURGICAL INSTRUMENT, filedApr. 18, 2016, which is incorporated herein by reference in itsentirety.

As illustrated in FIG. 60A, the carrier 4022 includes a carrier circuit4043 (FIG. 60C) separably couplable to a cartridge circuit 4024 of astaple cartridge 4008. The carrier circuit 4043 has a plurality ofelectrical contacts 4036. In addition, the carrier circuit 4043 includesa carrier connector-region 4013 comprising a plurality of connectors4038 that each defines a first electrical contact 4038 a and a secondelectrical contact 4038 b. The connectors 4038 are positioned such thata gap is maintained between the electrical contacts 4036 and the firstelectrical contacts 4038 a of the connectors 4038 in their neutralpositions. Each of the connectors 4038 comprises a curved portionprotruding from a supporting wall 4040. The second electrical contacts4038 b are defined at the curved portions of the connectors 4038. Whenthe staple cartridge 4008 is inserted in the carrier 4022, the externalelectrical contacts 4028 of the staple cartridge 4008 are configured toengage and move the connectors 4038 into a biased configuration wherethe electrical contacts 4036 are electrically coupled to thecorresponding first electrical contacts 4038 a of the connectors 4038.While the staple cartridge 4008 is seated in the carrier 4022, theexternal electrical contacts 4028 of the staple cartridge 4008 are alsoelectrically coupled to the corresponding second electrical contacts4038 b of the connectors 4038.

To ensure a robust electrical connection, one or more of the electricalconnectors 4038, external electrical contacts 4028, the electricalcontacts 4036, the electrical contacts 4038 a, and/or the electricalcontacts 4038 b can be coated, or at least partially coated, with afluid-repellant coating, and/or potted in an insulating material such assilicon to prevent fluid ingress. As illustrated in FIG. 60A, afluid-repellant coating is added to the electrical connectors 4038 andthe electrical contacts 4036. In at least one aspect, thefluid-repellant coating is added to all the electrical cables and/orconnections of a staple cartridge. One or more fluid-repellant coatingsmanufactured by Aculon, Inc., for example, can be used.

Further to the above, the electrical contacts 4038 b of thespring-biased electrical connectors 4038 include wearing features, orpoint contacts, 4039 in the form of a raised dome-shaped structureconfigured to remove or scratch off the fluid-repellant coating from theexternal electrical contacts 4028 of the staple cartridge 4008 thusestablishing an electrical connection with the staple cartridge 4008. Acompressible seal 4041 is configured to prevent, or at least resist,fluid ingress between a carrier 4022 and a staple cartridge 4008 seatedin the carrier 4022. The compressible seal 4041 can be comprised of acompressible material that snuggly fits between a carrier 4022 and astaple cartridge 4008 seated in the carrier 4022. As illustrated in FIG.60A, the compressible seal 4041 defines walls that define a perimeteraround, or at least partially around, the electrical connectors 4038 andthe external electrical contacts 4028 of the staple cartridge 4008 whenthe staple cartridge 4008 is seated in the carrier 4022.

Referring primarily to FIGS. 58-60, the carrier connector-region 4013and the cartridge connector-region 4017 are configured to facilitate anelectrical connection between the cartridge circuit 4024 and the carriercircuit 4043 when the staple cartridge 4008 is seated within the carrier4022. As illustrated in FIG. 60, the carrier connector-region 4013 islocated on a side wall 4009 of the carrier 4022. The carrierconnector-region 4013 is secured to an inner surface 4011 of the sidewall 4009. As illustrated in FIG. 59, the cartridge connector-region4017 is located on a side wall 4007 of the staple cartridge 4008. Thecartridge connector-region 4017 is secured to an outer surface 4005 ofthe side wall 4007. The carrier connector-region 4013 is configured toabut against the cartridge connector-region 4017 when the staplecartridge 4008 is seated in the carrier 4022. The compressible seal 4041prevents, or at least resists, fluid ingress between the carrierconnector-region 4013 and the cartridge connector-region 4017.Positioning the carrier connector-region 4013 and the cartridgeconnector-region 4017 on the corresponding side walls 4009 and 4007facilitates the establishment of an electrical connection between thestaple cartridge 4008 and the end effector 4000 by seating the staplecartridge 4008 within the carrier 4022. Positioning the carrierconnector-region 4013 and the cartridge connector-region 4017 on thecorresponding side walls 4009 and 4007 permits establishing a connectionbetween the carrier connector-region 4013 and the cartridgeconnector-region 4017 simply by seating the staple cartridge 4008 in thecarrier 4022.

As illustrated in FIG. 63, a first electrical interface 4042 is definedby the electrical contacts 4036 and 4038 a. The first electricalinterface 4042 is configured to be transitioned between an openconfiguration where the electrical contacts 4036 and 4038 a are spacedapart and a closed configuration where the electrical contacts 4036 and4038 a are electrically coupled. Likewise, a second electrical interface4044 is defined by the electrical contacts 4038 b and 4028. The secondelectrical interface 4044 is configured to be transitioned between anopen configuration where the electrical contacts 4038 b and 4028 arespaced apart and a closed configuration where the electrical contacts4038 b and 4028 are electrically coupled. Furthermore, a thirdelectrical interface 4046 is defined between the end effector 4000 and ahandle portion of a surgical stapling and cutting instrument. The thirdelectrical interface 4046 is also configured to be transitioned betweenan open configuration where the end effector 4000 is not attached to thehandle portion and a closed configuration where the end effector 4000 isattached to the handle portion.

The transition of the electrical interface 4042 from an openconfiguration to a closed configuration indicates that a staplecartridge has been attached to the carrier 4022. In addition, thetransition of the electrical interface 4044 from an open configurationto a closed configuration indicates that a correct type of staplecartridge has been attached to the carrier 4022. When the electricalinterface 4044 is in the closed configuration, the storage medium 4026of the staple cartridge 4008 can be accessed to obtain informationstored therein about staple cartridge 4008.

In certain instances, as illustrated in FIG. 63, the electricalinterfaces 4042, 4044, and 4046 and the cartridge-status circuit portion4032 are electrically connected in a control circuit 4048. In suchinstances, a safety mechanism can be incorporated to prevent the firingof the end effector 4000 if at least one of the electrical interface4042, the electrical interface 4044, the electrical interface 4046, andthe cartridge-status circuit portion 4032 is in an open configuration.Said another way, if the control circuit 4048 is in an openconfiguration, the safety mechanism prevents the firing of the endeffector 4000. In other words, if the end effector 4000 is not correctlyattached to the handle portion of the surgical instrument, if no staplecartridge is attached to the carrier 4022, if an incorrect staplecartridge is attached to the carrier 4022, and/or if a spent staplecartridge is attached to carrier 4022, the safety mechanism prevents thefiring of the end effector 4000.

In certain instances, one or more of the electrical interface 4042, theelectrical interface 4044, the electrical interface 4046, and thecartridge-status circuit portion 4032 are connected in parallel withnon-severable sections of the control circuit 4048 which helps avoid anysingle point failure due to a full interruption of the control circuit4048. This arrangement ensures a continued electrical connection withinthe control circuit 4048 in the event one or more of the electricalinterface 4042, the electrical interface 4044, the electrical interface4046, and the cartridge-status circuit portion 4032 is in an openconfiguration. For example, as illustrated in FIG. 63, the trace element4034 of the cartridge-status circuit portion 4032 is in parallel with afirst resistive element 4037 and in series with a second resistiveelement 4037′ to ensure continued operation and avoid a single pointfailure of the control circuit 4048 in the event the trace element 4034is severed. One or more sensors, including but not limited to voltageand/or current sensors, can be employed to detect a currentconfiguration and/or a transition between an open or severedconfiguration and a closed or intact configuration.

In certain instances, one or more of the electrical interface 4042, theelectrical interface 4044, the electrical interface 4046, and thecartridge-status circuit portion 4032 are not connected in series. Insuch instances, one or more of the electrical interface 4042, theelectrical interface 4044, the electrical interface 4046, and/or thecartridge-status circuit portion 4032 are configured to separatelyprovide feedback regarding their dedicated functions.

Referring to FIGS. 63-65, one or more of the electrical interface 4042,the electrical interface 4044, the electrical interface 4046, and thecartridge-status circuit portion 4032 can be implemented in the form ofa conductive gate 4060 transitionable between an open configuration, asillustrated in FIG. 64, and a closed configuration, as illustrated inFIG. 65. In the closed configuration, the conductive gate 4060 enablesan electrical connection between two end-points of an electrical circuitsuch as, for example, the control circuit 4048. The electricalconnection, however, is severed when the conductive gate 4060 istransitioned to the open configuration.

The conductive gate 4060 can be repeatedly transitioned between a closedconfiguration and an open configuration. The conductive gate 4060includes a pivot portion 4062 rotatably attached to a first end-point4068 of the control circuit 4048. The conductive gate 4060 is configuredto pivot about the first end-point 4068 between the open and closedconfigurations. The conductive gate 4060 further includes an attachmentportion 4066 spaced apart from the pivot portion 4062. A central bridgeportion 4064 extends between and connects the pivot portion 4062 and theattachment portion 4066. As illustrated in FIGS. 64 and 65, theattachment portion 4066 is in the form of a hook or latch configured toreleasably capture a second end-point 4069 of the control circuit 4048to transition the conductive gate 4060 from the open configuration tothe closed configuration. In certain instances, the attachment portion4066 may comprise a magnetic attachment or any other mechanicalattachment, for example. In at least one instance, the conductive gate4060 can be spring-biased in the closed configuration. Alternatively,the conductive gate 4060 can be spring-biased in the open configuration.

As illustrated in FIG. 65A, a safety mechanism 4047 of the surgicalinstrument may include a controller 4050 which may comprise a processor4052 and/or one or more storage mediums such as, for example, a memory4054. By executing instruction code stored in the memory 4054, theprocessor 4052 may control various components of the surgical instrumentsuch as a firing system 4056 and a user interface such as, for example,a display 4058. The controller 4050 keeps track of the statuses of theelectrical interface 4042, the electrical interface 4044, the electricalinterface 4046, and/or the cartridge-status circuit portion 4032. Asdescribed in greater detail below, the controller 4050 may, depending onthe reported statuses of one or more of the electrical interface 4042,the electrical interface 4044, the electrical interface 4046, and/or thecartridge-status circuit portion 4032, cause the firing system 4056 tobe deactivated and/or provide user feedback as to the reason for thedeactivation. In certain instances, the controller 4050 may identifyand/or aid a user in addressing the cause of the deactivation of thefiring system 4056. For example, the controller 4050 may alert a userthat an attached staple cartridge is spent or is not the correct type tobe used with the end effector 4000.

In various instances, the memory 4054 includes program instructionswhich, when executed by the processor 4052, cause the processor 4052 todetermine that a staple cartridge 4008 has been attached to the carrier4022 when a transition of the electrical interface 4042 to a closedconfiguration is detected by the processor 4052. In addition, the memory4054 may include program instructions which, when executed by theprocessor 4052, cause the processor 4052 to determine that that attachedstaple cartridge 4008 has already been spent or fired when a transitionof the electrical interface 4042 to a closed configuration is detectedby the processor 4052 but the cartridge-status circuit portion 4032 isin the open configuration. Further to the above, the memory 4054 mayalso include program instructions which, when executed by the processor4052, cause the processor 4052 to determine that a memory 4026 of anattached staple cartridge 4008 is accessible when a transition of theelectrical interface 4044 to a closed configuration is detected by theprocessor 4052. In addition, the processor 4052 may be configured toretrieve certain information stored in the memory 4026 of the attachedstaple cartridge 4008. In certain instances, detecting a closedconfiguration of the electrical interface 4042 while not detecting aclosed configuration of the electrical interface 4044 indicates that anincorrect staple cartridge is attached to the carrier 4022.

Further to the above, the memory 4054 may also include programinstructions which, when executed by the processor 4052, cause theprocessor 4052 to determine that a successful connection between the endeffector 4000 and the handle portion of the surgical instrument has beendetected when a transition of the electrical interface 4046 to a closedconfiguration is detected by the processor 4052.

Referring to FIG. 65B, a block diagram depicts a method 4071 of firing asurgical instrument that includes an end effector such as, for example,the end effector 4000. In a first step 4073, a firing trigger 4550 (FIG.80) is pressed while a cutting member of the end effector 4000 ispositioned proximally to a predetermined no-cartridge-lockout zone. Oneor more position sensors can be employed to determine the position ofthe cutting member. The firing trigger can be located on a handle of thesurgical instrument and can be pressed by a user, for example, to ininitiate a firing stroke of the surgical instrument. Next, a firstdecision block 4075 is configured to check whether the trace element4034 (FIG. 61) is intact, and a second decision block 4077 is configuredto check whether the memory 4026 (FIG. 59) can be read. If the traceelement 4034 is not intact or the memory 4026 cannot be read, the firinglockout is engaged, as indicated in step 4079. Then, once capturedtissue is released by unclamping the end effector 4000 at step 4070, anarticulation mode is re-engaged in step 4072. If, however, the traceelement 4034 is intact and the memory 4026 is read, the firing system4056 is permitted to proceed through the firing stroke, step 4074. Adecision block 4076 is configured to provide a threshold at apre-determined cutline at which point, the firing system 4056 is reset.Resetting the firing system 4056 can include returning the cuttingmember to a per-determined default position, as depicted in step 4078.As illustrated in step 4074 a, if the firing trigger 4550 is pressedwhile the cutting member of the end effector 4000 is positioned distalto the predetermined no-cartridge-lockout zone, the firing system 4056is permitted to proceed with the firing stroke.

Referring to FIGS. 66-70, a staple cartridge 4100 is similar in manyrespects to the staple cartridge 4008. The staple cartridge 4100 isreleasably attached to the end effector 4000. In addition, the staplecartridge 4100 includes a cartridge-status circuit 4102 for assessingwhether the staple cartridge 4100 is attached to an end effector 4000and/or whether an attached staple cartridge 4100 was previously fired.

As illustrated in FIG. 66, the staple cartridge 4100 comprises aconductive gate 4160 at a proximal portion 4103 of the staple cartridge4100. The conductive gate 4160 is movable between a first closedconfiguration (FIG. 68), a second closed configuration (FIG. 70), and anopen configuration (FIG. 69). A controller can be configured to assesswhether the staple cartridge 4100 is attached to an end effector 4000and/or whether an attached staple cartridge 4100 was previously fired bydetermining whether the conductive gate 4160 is at an openconfiguration, a first closed configuration, or a second closedconfiguration. In at least one instance, the first closed configurationis a partially closed configuration while the second closedconfiguration is a fully closed configuration.

In a closed configuration, the conductive gate 4160 extends across anelongate slot 4114 defined between a first deck portion 4112 a and asecond deck portion 4112 b of the staple cartridge 4100. The conductivegate 4160 extends between a first end-point 4168 of the cartridge-statuscircuit 4102 and a second end-point 4170 of the cartridge-status circuit4102. The first end-point 4168 is defined on a first side wall 4114 a ofthe elongate slot 4114 and the second end-point 4170 is defined on asecond side wall 4114 b of the elongate slot 4114. To connect the firstend-point 4168 and the second end-point 4170 in the closedconfiguration, the conductive gate 4160 bridges the elongate slot 4114,as illustrated in FIG. 68.

As illustrated in FIG. 66, the conductive gate 4160 includes a pivotportion 4162 rotatably attached to the first end-point 4168 of thecartridge-status circuit 4102. The conductive gate 4160 is configured topivot about the first end-point 4168 between the open, first closed, andsecond closed configurations. The conductive gate 4160 further includesan attachment portion 4166 spaced apart from the pivot portion 4162. Acentral bridge portion 4164 extends between and connects the pivotportion 4162 and the attachment portion 4166. As illustrated in FIG. 66,the attachment portion 4166 is in the form of a hook or latch configuredto be releasably captured by the second end-point 4170. The attachmentportion 4166 includes a “C” shaped ring 4171 configured to receive thesecond end-point 4170 in the second closed configuration. An opening4173 of the “C” shaped ring 4171 is slightly smaller than the secondend-point 4170. Accordingly, for the second end-point 4170 to bereceived within the “C” shaped ring 4171 an external force is needed topass the second end-point 4170 through the opening 4173 of the “C”shaped ring 4171 and bring the conductive gate 4160 to the second closedconfiguration, as illustrated in FIG. 68.

Although the conductive gate is spring-biased toward a closedconfiguration, the spring-biasing force is insufficient to bring theconductive gate 4160 to the second closed configuration. Accordingly, inthe absence of an external force to motivate the conductive gate 4160toward an open configuration or a second closed configuration, theconductive gate 4160 will swing, under the effect of the spring-biasingforce, to a resting position at the first closed configuration, asillustrated in FIG. 70. At the first closed configuration, anintermediate region 4175 between the “C” shaped ring 4171 of theattachment portion 4166 and the central bridge portion 4164 is incontact with the second end-point 4170. However, the second end-point4170 is not received within the “C” shaped ring 4171.

The staple cartridge 4100 further comprises a sled 4118 which is similarin many respects to the sled 4018. A firing member 4113 is configured tomotivate the sled 4118 distally from a proximal, unfired, or startposition toward a distal, fired, or end position during a staple firingstroke. In addition, the sled 4118 includes a catch member 4119configured to engage and transition the conductive gate 4160 from asecond closed configuration to an open configuration as the sled 4118 isadvanced distally from the proximal, unfired, or start position toward adistal, fired, or end position. Upon losing contact with the catchmember 4119, the conductive gate 4160 is configured to return to thefirst closed configuration from the open configuration under theinfluence of the spring-biasing force and in the absence of any externalforce.

Referring to FIG. 67, the catch member 4119 extends proximally from thesled 4118 and includes a proximal-extending portion 4119 a and anengagement portion 4119 b protruding from a proximal end of theproximal-extending portion 4119 a. The engagement portion 4119 b isarranged such that conductive gate 4160 is captured by the engagementportion 4119 b as the sled 4118 is advanced from the proximal, unfired,or start position toward the distal, fired, or end position to deploystaples during a firing stroke of the surgical stapling and cuttinginstrument.

At least a portion of the catch member 4119 may be constructed from anon-conductive material. In at least one example, the engagement portion4119 b is at least partially made from a non-conductive material.

Other arrangements and configurations of the catch member 4119 arecontemplated by the present disclosure. In at least one aspect, thecatch member 4119 can be a post extending away from a base 4118 a of thesled 4118, for example. In another instances, the catch member 4119 canbe in the form of a ramp wherein the conductive gate 4160 is configuredto engage a lower portion of the ramp and, as the sled 4118 is advanceddistally, the ramp transitions the conductive gate 4160 to an openconfiguration. Once the conductive gate 4160 reaches the top of theramp, the spring-biasing force returns the conductive gate 4160 to afirst closed position.

Referring to FIGS. 68-71, the first closed configuration, the secondclosed configuration, and the open configuration represent a firstresistance-status, a second resistance-status, and an infiniteresistance-status, respectively, wherein the first resistance-status isdifferent than the second resistance-status and the infiniteresistance-status, and wherein the second resistance-status is differentthan the first resistance-status and the infinite resistance-status. Bysensing which of the three statuses is current and/or by sensingtransitions between the statuses, a controller 4050 (FIG. 71) candetermine whether the staple cartridge 4100 is attached to an endeffector 4000 and/or whether an attached staple cartridge 4100 waspreviously fired.

The conductive gate 4160 can be configured to define a first resistancewhen the conductive gate 4160 is at the first closed configuration and asecond resistance, different than the first resistance, when theconductive gate 4160 is at the second closed configuration. Thecontroller 4050 may comprise a processor 4052 and/or one or more storagemediums such as, for example, a memory 4054. By executing instructioncode stored in the memory 4054, the processor 4052 may identify acurrent resistance-status of the conductive gate 4160. The controller4050 may, depending on the detected resistance-status, perform one ormore function such as, for example, causing the firing system 4056 tobecome inactivated and/or providing user feedback as to the reason forsuch deactivation.

In various instances, the memory 4054 includes program instructionswhich, when executed by the processor 4052, cause the processor 4052 todetermine that an unspent or unfired staple cartridge 4100 is attachedto the carrier 4022 when a second resistance-status is detected by theprocessor 4052. In addition, the memory 4054 may include programinstructions which, when executed by the processor 4052, cause theprocessor 4052 to determine that a spent or previously fired staplecartridge 4100 is attached to the carrier 4022 when a firstresistance-status is detected by the processor 4052. The memory 4054 mayinclude program instructions which, when executed by the processor 4052,cause the processor 4052 to determine that no staple cartridge isattached to the carrier 4022 when an infinite resistance-status isdetected by the processor 4052.

The controller 4050 can be configured to make a determination as towhether a staple cartridge 4008 is detected upon activation or poweringof the surgical stapling and cutting instrument by performing a firstreading, or a plurality of readings, of the resistance-status. If aninfinite resistance-status is detected, the controller 4050 may theninstruct a user through the display 4058, for example, to load or inserta staple cartridge 4008 into the carrier 4022. If the controller 4050detects that a staple cartridge 4008 has been attached, the controller4050 may determine whether the attached staple cartridge has beenpreviously fired by performing a second reading, or a plurality ofreadings, of the resistance-status. If a first resistance-status isdetected, the controller 4050 may instruct the user that the attachedstaple cartridge 4008 has been previously fired and/or to replace thestaple cartridge 4008.

The controller 4050 employs a resistance-status detector 4124 to detecta current resistance-status and, in turn, determine whether theconductive gate 4160 is in the open configuration, the first closedconfiguration, or the second closed configuration. In at least oneaspect, the resistance-status detector 4124 may comprise a currentsensor. For example, the controller 4050 may cause a predeterminedvoltage potential to be generated between the first end-point 4168 andthe second end-point 4170, and then measure the current passing throughthe conductive gate 4160. If the measured current corresponds to thefirst resistance, the controller 4050 determines that the conductivegate 4160 is at the first closed configuration. On the other hand, ifthe measured current corresponds to the second resistance, thecontroller determines that the conductive gate 4160 is at the secondclosed configuration. Finally, if no current is detected, the controller4050 determines that the conductive gate 4160 is at the openconfiguration. In at least one aspect, the resistance-status detector4124 may comprise other sensors such as, for example, a voltage sensor.

In various instances, one or more controllers of the present disclosuresuch as, for example, the controller 4050 may be implemented usingintegrated and/or discrete hardware elements, software elements, and/ora combination of both. Examples of integrated hardware elements mayinclude processors, microprocessors, controllers, integrated circuits,application specific integrated circuits (ASIC), programmable logicdevices (PLD), digital signal processors (DSP), field programmable gatearrays (FPGA), logic gates, registers, semiconductor devices, chips,microchips, chip sets, microcontroller, system-on-chip (SoC), and/orsystem-in-package (SIP). Examples of discrete hardware elements mayinclude circuits and/or circuit elements (e.g., logic gates, fieldeffect transistors, bipolar transistors, resistors, capacitors,inductors, relay and so forth). In other embodiments, one or morecontrollers of the present disclosure may include a hybrid circuitcomprising discrete and integrated circuit elements or components on oneor more substrates, for example.

In one embodiment, as illustrated in FIG. 72, a circuit 4080 maycomprise a controller comprising one or more processors 4082 (e.g.,microprocessor, microcontroller) coupled to at least one memory circuit4084. The at least one memory circuit 4084 stores machine executableinstructions that when executed by the processor 4082, cause theprocessor 4082 to execute machine instructions to implement one or moreof the functions performed by one or more controllers of the presentdisclosure such as, for example, the controller 4050.

The processor 4082 may be any one of a number of single or multi-coreprocessors known in the art. The memory circuit 4084 may comprisevolatile and non-volatile storage media. In one embodiment, asillustrated in FIG. 72, the processor 4082 may include an instructionprocessing unit 4086 and an arithmetic unit 4088. The instructionprocessing unit may be configured to receive instructions from the onememory circuit 4084.

In one embodiment, a circuit 4090 may comprise a finite state machinecomprising a combinational logic circuit 4092, as illustrated in FIG.73, configured to implement one or more of the functions performed byone or more controllers of the present disclosure such as, for example,the controller 4050. In one embodiment, a circuit 4200 may comprise afinite state machine comprising a sequential logic circuit, asillustrated in FIG. 74. The sequential logic circuit 4200 may comprisethe combinational logic circuit 4202 and at least one memory circuit4204, for example. The at least one memory circuit 4204 can store acurrent state of the finite state machine, as illustrated in FIG. 74.The sequential logic circuit 4200 or the combinational logic circuit4202 can be configured to implement one or more of the functionsperformed by one or more controllers of the present disclosure such as,for example, the controller 4050. In certain instances, the sequentiallogic circuit 4200 may be synchronous or asynchronous.

In other embodiments, the circuit may comprise a combination of theprocessor 4082 and the finite state machine to implement one or more ofthe functions performed by one or more controllers of the presentdisclosure such as, for example, the controller 4050. In otherembodiments, the finite state machine may comprise a combination of thecombinational logic circuit 4090 and the sequential logic circuit 4200.

In some cases, various embodiments may be implemented as an article ofmanufacture. The article of manufacture may include a computer readablestorage medium arranged to store logic, instructions and/or data forperforming various operations of one or more embodiments. In variousembodiments, for example, the article of manufacture may comprise amagnetic disk, optical disk, flash memory or firmware containingcomputer program instructions suitable for execution by a generalpurpose processor or application specific processor. The embodiments,however, are not limited in this context.

The functions of the various functional elements, logical blocks,modules, and circuits elements described in connection with theembodiments disclosed herein may be implemented in the general contextof computer executable instructions, such as software, control modules,logic, and/or logic modules executed by the processing unit. Generally,software, control modules, logic, and/or logic modules comprise anysoftware element arranged to perform particular operations. Software,control modules, logic, and/or logic modules can comprise routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, control modules, logic, and/or logicmodules and techniques may be stored on and/or transmitted across someform of computer-readable media. In this regard, computer-readable mediacan be any available medium or media useable to store information andaccessible by a computing device. Some embodiments also may be practicedin distributed computing environments where operations are performed byone or more remote processing devices that are linked through acommunications network. In a distributed computing environment,software, control modules, logic, and/or logic modules may be located inboth local and remote computer storage media including memory storagedevices.

Additionally, it is to be appreciated that the embodiments describedherein illustrate example implementations, and that the functionalelements, logical blocks, modules, and circuits elements may beimplemented in various other ways which are consistent with thedescribed embodiments. Furthermore, the operations performed by suchfunctional elements, logical blocks, modules, and circuits elements maybe combined and/or separated for a given implementation and may beperformed by a greater number or fewer number of components or modules.As will be apparent to those of skill in the art upon reading thepresent disclosure, each of the individual embodiments described andillustrated herein has discrete components and features which may bereadily separated from or combined with the features of any of the otherseveral aspects without departing from the scope of the presentdisclosure. Any recited method can be carried out in the order of eventsrecited or in any other order which is logically possible

The foregoing detailed description has set forth various embodiments ofthe devices and/or processes via the use of block diagrams, flowcharts,and/or examples. Insofar as such block diagrams, flowcharts, and/orexamples contain one or more functions and/or operations, it will beunderstood by those within the art that each function and/or operationwithin such block diagrams, flowcharts, or examples can be implemented,individually and/or collectively, by a wide range of hardware, software,firmware, or virtually any combination thereof. In one embodiment,several portions of the subject matter described herein may beimplemented via Application Specific Integrated Circuits (ASICs), FieldProgrammable Gate Arrays (FPGAs), digital signal processors (DSPs), orother integrated formats. Those skilled in the art will recognize,however, that some aspects of the embodiments disclosed herein, in wholeor in part, can be equivalently implemented in integrated circuits, asone or more computer programs running on one or more computers (e.g., asone or more programs running on one or more computer systems), as one ormore programs running on one or more processors (e.g., as one or moreprograms running on one or more microprocessors), as firmware, or asvirtually any combination thereof, and that designing the circuitryand/or writing the code for the software and or firmware would be wellwithin the skill of one of skill in the art in light of this disclosure.In addition, those skilled in the art will appreciate that themechanisms of the subject matter described herein are capable of beingdistributed as a program product in a variety of forms, and that anillustrative embodiment of the subject matter described herein appliesregardless of the particular type of signal bearing medium used toactually carry out the distribution. Examples of a signal bearing mediuminclude, but are not limited to, the following: a recordable type mediumsuch as a floppy disk, a hard disk drive, a Compact Disc (CD), a DigitalVideo Disk (DVD), a digital tape, a computer memory, etc.; and atransmission type medium such as a digital and/or an analogcommunication medium (e.g., a fiber optic cable, a waveguide, a wiredcommunications link, a wireless communication link (e.g., transmitter,receiver, transmission logic, reception logic, etc.), etc.).

Various mechanisms are described herein for detecting attachment of astaple cartridge to a surgical stapling and cutting instrument. Inaddition, various mechanisms are described herein for determiningwhether an attached staple cartridge is spent. Since firing a surgicalstapling and cutting instrument in the absence of an unspent andproperly attached staple cartridge presents a significant danger to thepatient, an electromagnetic lockout mechanism 4300 is employed inconnection with a firing system such as, for example, the firing system4056 to prevent firing the surgical stapling and cutting instrument if astaple cartridge is not attached to a carrier 4022 of the surgicalstapling and cutting instrument, or if an attached staple cartridge isspent.

Referring to FIGS. 75-78, a lockout mechanism 4300 for a surgicalstapling and cutting instrument interacts with a drive train 4302 of thefiring system 4056. The lockout mechanism 4300 comprises anelectro-mechanical lockout that includes a latch 4304 transitionablebetween a locked configuration with a drive train 4302 and an unlockedconfiguration with the drive train 4302. In the unlocked configuration,as illustrated in FIG. 77, the drive train 4302 is permitted to advanceto deploy staples into tissue and/or cut the tissue. In the lockedconfiguration, illustrated in FIG. 76, the drive train 4302 is preventedfrom being advanced either because no staple cartridge is attached tothe carrier 4022 or an attached staple cartridge is spent.

As illustrated in FIG. 75, the drive train 4302 includes a hole 4306configured to receive the latch 4304 when the latch 4304 is in thelocked configuration. An electrical circuit 4308 is configured toselectively transition the latch 4304 between the locked configurationand the unlocked configuration. The electrical circuit 4308 includes anelectrical magnet 4310 which is configured to selectively transition thelockout mechanism 4300 between the locked configuration and the unlockedconfiguration. The electrical circuit 4308 further includes a powersource 4312 and a power relay 4314 configured to selectively transmitenergy to power the electrical magnet 4310. Powering the electricalmagnet 4310 causes the lockout mechanism 4300 to be transitioned from alocked configuration to an unlocked configuration. In an alternativeembodiment, powering the electrical magnet 4310 can cause the lockoutmechanism 4300 to be transitioned from an unlocked configuration to alocked configuration.

The electrical magnet 4310 is configured to selectively move the latch4304 between a first position, where the latch 4304 is at leastpartially positioned in the hole 4306, and a second position, where thelatch 4304 is outside the hole 4306. In other words, the electricalmagnet 4310 is configured to selectively move the latch 4304 between afirst position, where the latch 4304 interferes with advancement of thedrive train 4302, and a second position, where the latch 4304 permitsadvancement of the drive train 4302. In an alternative embodiment, adrive train of the firing system 4056 comprises a protrusion or a latchconfigured to be received in a hole of a corresponding structure that isoperably attached to the electrical magnet 4310. In such an embodiment,the electrical magnet 4310 is configured to selectively move thestructure comprising the hole between the first position and the secondposition. Although a latch and a corresponding structure that includes ahole are described in connection with the lockout mechanism 4300, it isunderstood that other mechanical mating members can be employed.

As illustrated in FIG. 75, the lockout mechanism 4300 further includes apiston 4315 comprising a biasing member such as, for example, a spring4316 movable between an first compressed configuration, as illustratedin FIG. 76, and a second compressed configuration, as illustrated inFIG. 77. In the second compressed configuration, the spring 4316 liftsor maintains the latch 4304 out of engagement with the drive train 4302,as illustrated in FIG. 77. When the spring 4316 is allowed to return tothe first compressed configuration, the latch 4304 is also returned intoengagement with the drive train 4302, as illustrated in FIG. 76.

Further to the above, a permanent magnet 4318 is attached to the latch4304. Alternatively, the latch 4304, or at least a portion thereof, canbe made from a ferromagnetic material. When the electrical circuit 4308activates the electrical magnet 4310, the permanent magnet 4318 isattracted toward the electrical magnet 4310 causing the spring 4316 tobe biased or compressed. In addition, the permanent magnet 4318 causesthe latch 4304 to be lifted or transitioned out of engagement with thedrive train 4302, as illustrated in FIG. 77. However, when theelectrical circuit 4308 deactivates the electrical magnet 4310, thebiasing force of the spring 4316 returns the permanent magnet 4318 andthe latch 4304 to their original positions where the latch 4304 isengaged with the drive train 4302, as illustrated in FIG. 76.

Referring to FIG. 78, a safety mechanism 4347 of a surgical stapling andcutting instrument may include a controller 4050 which may comprise aprocessor 4052 and/or one or more storage mediums such as, for example,a memory 4054. By executing instruction code stored in the memory 4054,the processor 4052 may control activating and/or deactivating thelockout mechanism 4300. The processor 4052 may receive input 4320regarding whether a staple cartridge is attached to the carrier 4022and/or whether an attached staple cartridge is spent. Depending on thereceived input, the processor 4052 may activate or deactivate thelockout mechanism 4300 to permit or prevent the firing system 4056 frombeing used to perform a staple firing stroke.

FIGS. 80-82B generally depict a motor-driven surgical fastening andcutting instrument 4500. As illustrated in FIGS. 80 and 81, the surgicalinstrument 4500 includes a handle assembly 4502, a shaft assembly 4504,and a power assembly 4506 (“power source,” “power pack,” or “batterypack”). The shaft assembly 4504 includes an end effector 4508 which canbe configured to act as an endocutter for clamping, severing, and/orstapling tissue, although, in other instances, different types of endeffectors may be used, such as end effectors for other types of surgicaldevices, graspers, cutters, staplers, clip appliers, access devices,drug/gene therapy devices, ultrasound devices, RF device, and/or laserdevices, for example. Several RF devices may be found in U.S. Pat. No.5,403,312, entitled ELECTROSURGICAL HEMOSTATIC DEVICE, which issued onApr. 4, 1995, and U.S. patent application Ser. No. 12/031,573, entitledSURGICAL FASTENING AND CUTTING INSTRUMENT HAVING RF ELECTRODES, filedFeb. 14, 2008, the entire disclosures of which are incorporated hereinby reference in their entirety.

Referring primarily to FIGS. 81-82B, the handle assembly 4502 can beemployed with a plurality of interchangeable shaft assemblies such as,for example, the shaft assembly 4504. Such interchangeable shaftassemblies may comprise surgical end effectors such as, for example, theend effector 4508 that can be configured to perform one or more surgicaltasks or procedures. Examples of suitable interchangeable shaftassemblies are disclosed in U.S. Provisional Patent Application Ser. No.61/782,866, entitled CONTROL SYSTEM OF A SURGICAL INSTRUMENT, and filedMar. 14, 2013, the entire disclosure of which is hereby incorporatedherein by reference in its entirety.

Referring primarily to FIG. 81, the handle assembly 4502 may comprise ahousing 4510 that contains a handle 4512 that may be configured to begrasped, manipulated and actuated by a clinician. However, it will beunderstood that the various arrangements of the various forms ofinterchangeable shaft assemblies disclosed herein may also beeffectively employed in connection with robotically-controlled surgicalsystems. Thus, the term “housing” may also encompass a housing orsimilar portion of a robotic system that houses or otherwise operablysupports at least one drive system that is configured to generate andapply at least one control motion which could be used to actuate theinterchangeable shaft assemblies disclosed herein and their respectiveequivalents. For example, the interchangeable shaft assemblies disclosedherein may be employed with various robotic systems, instruments,components and methods disclosed in U.S. patent application Ser. No.13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT, now U.S. Pat. No. 9,072,535, the entire disclosure of whichis incorporated by reference herein.

Referring again to FIG. 81, the handle assembly 4502 operably supports aplurality of drive systems therein that can be configured to generateand apply various control motions to corresponding portions of theinterchangeable shaft assembly that is operably attached thereto. Forexample, the handle assembly 4502 operably supports a first or closuredrive system, which is employed to apply closing and opening motions tothe shaft assembly 4504 while operably attached or coupled to the handleassembly 4502. The handle assembly 4502 operably supports a firing drivesystem that is configured to apply firing motions to correspondingportions of the interchangeable shaft assembly attached thereto.

Referring primarily to FIGS. 82A and 82B, the handle assembly 4502includes a motor 4514 which is controlled by a motor control circuit4515 and is employed by the firing system of the surgical instrument4500. The motor 4514 may be a DC brushed driving motor having a maximumrotation of, approximately, 25,000 RPM. Alternatively, the motor 4514may include a brushless motor, a cordless motor, a synchronous motor, astepper motor, or any other suitable electric motor. The motor controlcircuit 4515 may comprise an H-Bridge field-effect transistors (FETs)4519, as illustrated in FIGS. 82A and 82B. The motor 4514 is powered bythe power assembly 4506 (FIGS. 82A and 82B) which can be releasablymounted to the handle assembly 4502 for supplying control power to thesurgical instrument 4500. The power assembly 4506 comprises a batterywhich may include a number of battery cells connected in series that canbe used as the power source to power the surgical instrument 4500. Thebattery cells of the power assembly 4506 may be replaceable and/orrechargeable. In at least one example, the battery cells can beLithium-Ion batteries which can be separably couplable to the powerassembly 4506.

The shaft assembly 4504 includes a shaft assembly controller 4522 whichcommunicates with the power management controller 4516 through aninterface while the shaft assembly 4504 and the power assembly 4506 arecoupled to the handle assembly 4502. The interface may comprise a firstinterface portion 4525 which includes one or more electric connectorsfor coupling engagement with corresponding shaft assembly electricconnectors and a second interface portion 4527 which includes one ormore electric connectors for coupling engagement with correspondingpower assembly electric connectors to permit electrical communicationbetween the shaft assembly controller 4522 and the power managementcontroller 4516 while the shaft assembly 4504 and the power assembly4506 are coupled to the handle assembly 4502. One or more communicationsignals can be transmitted through the interface to communicate one ormore of the power requirements of the attached interchangeable shaftassembly 4504 to the power management controller 4516. In response, thepower management controller modulates the power output of the battery ofthe power assembly 4506, as described below in greater detail, inaccordance with the power requirements of the attached shaft assembly4504. One or more of the electric connectors comprise switches which canbe activated after mechanical coupling engagement of the handle assembly4502 to the shaft assembly 4504 and/or to the power assembly 4506 toallow electrical communication between the shaft assembly controller4522 and the power management controller 4516.

The interface facilitates transmission of the one or more communicationsignals between the power management controller 4516 and the shaftassembly controller 4522 by routing such communication signals through amain controller 4517 residing in the handle assembly 4502.Alternatively, the interface can facilitate a direct line ofcommunication between the power management controller 4516 and the shaftassembly controller 4522 through the handle assembly 4502 while theshaft assembly 4504 and the power assembly 4506 are coupled to thehandle assembly 4502.

The main controller 4517 may be any single core or multicore processorsuch as those known under the trade name ARM Cortex by TexasInstruments. The surgical instrument 4500 may comprise a powermanagement controller 4516 such as a safety microcontroller platformcomprising two microcontroller-based families such as TMS570 and RM4xknown under the trade name Hercules ARM Cortex R4, also by TexasInstruments. Nevertheless, other suitable substitutes formicrocontrollers and safety processor may be employed, withoutlimitation. The safety processor may be configured specifically for IEC61508 and ISO 26262 safety critical applications, among others, toprovide advanced integrated safety features while delivering scalableperformance, connectivity, and memory options.

The main controller 4517 may be an LM 4F230H5QR, available from TexasInstruments. The Texas Instruments LM4F230H5QR is an ARM Cortex-M4FProcessor Core comprising on-chip memory of 256 KB single-cycle flashmemory, or other non-volatile memory, up to 40 MHz, a prefetch buffer toimprove performance above 40 MHz, a 32 KB single-cycle serial randomaccess memory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available for the productdatasheet. The present disclosure should not be limited in this context.

The power assembly 4506 includes a power management circuit whichcomprises the power management controller 4516, a power modulator 4538,and a current sense circuit 4536. The power management circuit isconfigured to modulate power output of the battery based on the powerrequirements of the shaft assembly 4504 while the shaft assembly 4504and the power assembly 4506 are coupled to the handle assembly 4502. Forexample, the power management controller 4516 can be programmed tocontrol the power modulator 4538 of the power output of the powerassembly 4506 and the current sense circuit 4536 is employed to monitorpower output of the power assembly 4506 to provide feedback to the powermanagement controller 4516 about the power output of the battery so thatthe power management controller 4516 may adjust the power output of thepower assembly 4506 to maintain a desired output.

It is noteworthy that one or more of the controllers of the presentdisclosure may comprise one or more processors and/or memory units whichmay store a number of software modules. Although certain modules and/orblocks of the surgical instrument 4500 may be described by way ofexample, it can be appreciated that a greater or lesser number ofmodules and/or blocks may be used. Further, although various instancesmay be described in terms of modules and/or blocks to facilitatedescription, such modules and/or blocks may be implemented by one ormore hardware components, e.g., processors, Digital Signal Processors(DSPs), Programmable Logic Devices (PLDs), Application SpecificIntegrated Circuits (ASICs), circuits, registers and/or softwarecomponents, e.g., programs, subroutines, logic and/or combinations ofhardware and software components.

The surgical instrument 4500 may comprise an output device 4542 whichincludes one or more devices for providing a sensory feedback to a user.Such devices may comprise visual feedback devices (e.g., an LCD displayscreen, LED indicators), audio feedback devices (e.g., a speaker, abuzzer) or tactile feedback devices (e.g., haptic actuators). The outputdevice 4542 may comprise a display 4543 which may be included in thehandle assembly 4502. The shaft assembly controller 4522 and/or thepower management controller 4516 can provide feedback to a user of thesurgical instrument 4500 through the output device 4542. The interface4524 can be configured to connect the shaft assembly controller 4522and/or the power management controller 4516 to the output device 4542.The reader will appreciate that the output device 4542 can instead beintegrated with the power assembly 4506. In such circumstances,communication between the output device 4542 and the shaft assemblycontroller 4522 may be accomplished through the interface 4524 while theshaft assembly 4504 is coupled to the handle assembly 4502.

Having described a surgical instrument 4500 in general terms, thedescription now turns to a detailed description of variouselectrical/electronic component of the surgical instrument 4500. Forexpedience, any references herein to the surgical instrument 4500 shouldbe construed to refer to the surgical instrument 4500 shown inconnection with FIGS. 80-82B. Turning to FIG. 79, a circuit 4700 isdepicted. The circuit 4700 is configured to control a powered surgicalinstrument, such as the surgical instrument 4500 illustrated in FIG. 80.The circuit 4700 is configured to control one or more operations of thepowered surgical instrument 4500. The circuit 4700 includes a safetyprocessor 4704 and a main or primary processor 4702. The safetyprocessor 4704 and/or the primary processor 4702 are configured tointeract with one or more additional circuit elements to controloperation of the powered surgical instrument 4500. The primary processor4702 comprises a plurality of inputs coupled to one or more circuitelements. The circuit 4700 can be a segmented circuit. In variousinstances, the circuit 4700 may be implemented by any suitable circuit,such as a printed circuit board assembly (PCBA) within the poweredsurgical instrument 4500.

It should be understood that the term processor as used herein includesany microprocessor, microcontroller, or other basic computing devicethat incorporates the functions of a computer's central processing unit(CPU) on an integrated circuit or at most a few integrated circuits. Theprocessor is a multipurpose, programmable device that accepts digitaldata as input, processes it according to instructions stored in itsmemory, and provides results as output. It is an example of sequentialdigital logic, as it has internal memory. Processors operate on numbersand symbols represented in the binary numeral system.

The primary processor 4702 is any single core or multicore processorsuch as those known under the trade name ARM Cortex by TexasInstruments. The safety processor 4604 may be a safety microcontrollerplatform comprising two microcontroller-based families such as TMS570and RM4x known under the trade name Hercules ARM Cortex R4, also byTexas Instruments. Nevertheless, other suitable substitutes formicrocontrollers and safety processor may be employed, withoutlimitation. In one embodiment, the safety processor 4704 may beconfigured specifically for IEC 61508 and ISO 26262 safety criticalapplications, among others, to provide advanced integrated safetyfeatures while delivering scalable performance, connectivity, and memoryoptions.

The primary processor 4702 may be an LM 4F230H5QR, available from TexasInstruments. The Texas Instruments LM4F230H5QR is an ARM Cortex-M4FProcessor Core comprising on-chip memory of 256 KB single-cycle flashmemory, or other non-volatile memory, up to 40 MHz, a prefetch buffer toimprove performance above 40 MHz, a 32 KB single-cycle serial randomaccess memory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available for the productdatasheet. Other processors may be readily substituted and, accordingly,the present disclosure should not be limited in this context. Examplesof powered surgical instruments that include primary processors andsafety processors are described in U.S. Patent Application PublicationNo. 2015/0272574, entitled POWER MANAGEMENT THROUGH SLEEP OPTIONS OFSEGMENTED CIRCUIT AND WAKE UP CONTROL, filed Mar. 26, 2014, the entiredisclosure of which is incorporated herein by reference.

The safety processor 4704 is configured to implement a watchdog functionwith respect to one or more operations of the powered surgicalinstrument 4500. In this regard, the safety processor 4704 employs thewatchdog function to detect and recover from malfunctions of the primaryprocessor 4702. During normal operation, the safety processor 4704monitors for hardware faults or program errors of the primary processor4702 and to initiate corrective action or actions. The correctiveactions may include placing the primary processor 4702 in a safe stateand restoring normal system operation. In at least one aspect, theprimary processor 4702 and the safety processor 4704 operate in aredundant mode.

The primary processor 4702 and the safety processor 4704 are housed in ahandle portion of the powered surgical stapling and cutting instrument4500. At least one of the primary processor 4702 and the safetyprocessor 4704 is in communication with a shaft processor 4706 throughan interface 4707. The shaft processor 4706 is configured to receiveinput from a cartridge detection system 4709 configured to detectwhether an unspent staple cartridge has been attached to the poweredsurgical stapling and cutting instrument 4500.

The circuit 4700 further includes a motor 4714 operably coupled to afiring member of the powered surgical stapling and cutting instrument4500. One or more rotary position encoders 4741 can be configured toprovide feedback to the primary processor 4702 and/or the safetyprocessor 4704 as to the operational status of the motor 4714. A motordriver, including a metal-oxide-semiconductor field-effect transistor(MOSFET) 4711, controls power delivery to the motor 4714 from a powersource 4713. The MOSFET 4711 is controlled by an AND logic gate 4717. Ahigh output of the AND logic gate 4717 causes the MOSFET 4711 to beactivated, which causes the motor 4714 to run. The high output of theAND logic gate 4717 depends on receiving an input from the primaryprocessor 4702 and the safety processor 4704, as illustrated in FIG. 79.The primary processor 4702 and the safety processor 4704 are configuredto independently determine whether to allow the motor 4714 to run. Saidanother way, the primary processor 4702 and the safety processor 4704are configured to independently determine whether to permit advancementof the firing member of the powered surgical stapling and cuttinginstrument 4500.

In the event of an agreement, where both of the primary processor 4702and the safety processor 4704 determine to run the motor 4714, the ANDlogic gate 4717 produces a high output causing the MOSFET 4711 to beactivated thereby allowing the motor 4714 to run and, in turn, thefiring member to be advanced to fire the powered surgical stapling andcutting instrument 4500. However, in the event of a disagreement, whereonly one of the primary processor 4702 and the safety processor 4704determines to run the motor 4714 while the other one of the primaryprocessor 4702 and the safety processor 4704 determines not to run themotor 4714, the AND logic gate 4717 fails to produce a high output and,in turn, the MOSFET 4711 remains inactive.

Further to the above, the decision as to whether to run the motor 4714depends, at least in part, on information communicated to the primaryprocessor 4702 and/or the safety processor 4704 through the interface4707 regarding whether or not an unspent staple cartridge has beenattached to the powered surgical stapling and cutting instrument 4500.As described in greater detail elsewhere herein, a cartridge detectionsystem 4709 can be employed to determine, among other things, whether ornot an unspent staple cartridge, is attached to the powered surgicalstapling and cutting instrument 4500.

Referring to FIGS. 79A-79B, a translatable staple firing member 4460 ofa stapling assembly 4400 of the powered surgical stapling and cuttinginstrument 4500 is movable between a proximal, unfired, or startposition and a distal, fired, or end position along a staple firing path4463. A detectable magnetic element 4461, for example, is mounted to thestaple firing member 4460 which moves along, or at least substantiallyalong, the staple firing path 4463. In at least one instance, themagnetic element 4461 is a permanent magnet, for example, which iscomprised of iron, nickel, and/or any other suitable material. Thecartridge detection system 4709 comprises a first, or proximal, sensor4401′ and a second, or distal, sensor 4401 which are configured todetect the magnetic element 4461 as it moves along the staple firingpath 4463 with the staple firing member 4460. The first sensor 4401′ andthe second sensor 4401 each comprise a Hall Effect sensor; however, thesensors 4401′ and 4401 can comprise any suitable sensor. The sensors4401′ and 4401 output a voltage that varies depending on theirrespective distances from the magnetic element 4461 (a higher voltage isoutput when the distance is small and a lesser voltage is output whenthe distance is great).

Further to the above, the cartridge detection system 4709 comprises asensor circuit 4708 including, among other things, a voltage source4403, for example, in communication with the sensors 4401′ and 4401which supplies power to the sensors 4401′ and 4401. The sensor circuit4708 further comprises a first switch 4405′ in communication with thefirst sensor 4401′ and a second switch 4405 in communication with thesecond sensor 4401. In at least one instance, the switches 4401′ and4401 each comprise a transistor, such as a FET, for example. The outputsof the sensors 4401′, 4401 are connected to the central (gate) terminalof the switches 4405′, 4405, respectively. Prior to the firing stroke ofthe staple firing member 4460, the output voltages from the sensors4401′, 4401 are high so that the first switch 4405′ and the secondswitch 4405 are in closed conditions.

When the magnetic element 4461 passes by the first sensor 4401′, thevoltage output of the first sensor 4401′ is sufficient to change thefirst switch between a closed condition and an open condition.Similarly, the voltage output of the second sensor 4401 is sufficient tochange the second switch 4405 between a closed condition and an opencondition when the magnetic element 4461 passes by the second sensor4401. When both of the switches 4405′ and 4405 are in an open condition,a ground potential is applied to an operational amplifier circuit 4406.The operational amplifier circuit 4406 is in signal communication withan input channel of a shaft processor 4706 of the motor controller and,when a ground potential is applied to the operational amplifier circuit4406, the processor 4706 receives a ground signal from the circuit 4406.

When the processor 4706 receives a ground signal from the circuit 4406,the processor 4706 can determine that the staple firing stroke has beencompleted and that the staple cartridge positioned in the staplingassembly 4400 has been completely spent. Other embodiments areenvisioned in which the sensor system is configured to detect a partialfiring stroke of the staple firing member 4460 and supply a signal tothe processor 4706 that indicates that the staple cartridge has been atleast partially spent. In either event, the motor controller can beconfigured to prevent the staple firing member 4460 from performinganother firing stroke until the staple cartridge has been replaced withan unspent cartridge. In at least one instance, further to the above,the sensor system comprises a sensor configured to detect whether thespent cartridge has been detached from the stapling assembly and/orwhether an unspent cartridge has been assembled to the staplingassembly.

Further to the above, the sensor system can be configured to detectwhether the staple firing member 4460 has been retracted along aretraction path 4462. In at least one instance, the magnetic element4461 can be detected by the sensor 4401 as the magnetic element 4461 isretracted along the path 4462 and change the second switch 4405 backinto a closed condition. Similarly, the magnetic element 4461 can bedetected by the sensor 4401′ as the magnetic element 4461 is retractedalong the path 4463 and change the first switch 4405′ back into a closedcondition. By closing the switches 4405 and 4405′, the voltage polarityfrom the battery 4403 is applied to the circuit 4406 and, as a result,the processor 4706 receives a Vcc signal from the circuit 4406 on itsinput channel.

Further to the above, the cartridge detection system 4709 includes acartridge circuit 4724. The cartridge circuit 4624 is similar in manyrespects to the cartridge circuit 4024 (FIG. 59). For example, thecartridge circuit 4724 includes a trace element 4734 which istransitioned between a severed status, where the staple cartridge isspent, and an intact status, where the staple cartridge is unspent. Asillustrated in FIG. 79, the trace element 4734 is positioned in parallelwith a first resistive element 4737 and in series with a secondresistive element 4737′ to insure that the detection of failure of thesensor or interruption of its circuit is not merely lack of signaloutput. One or more sensors, including but not limited to voltage and/orcurrent sensors, can be employed to detect a current status and/or atransition between severed status and an intact status.

As illustrated in FIG. 79, accurate communications between theprocessors 4702, 4704, and 4706 can be ensured using security codes suchas, for example, cyclic redundancy checks (CRC) which areerror-detecting codes attached to data communications to detectaccidental changes in communicated data which may occur during datatransmission. Blocks of data entering these systems get a short checkvalue attached, based on the remainder of a polynomial division of theircontents. In certain instances, two parameter sets with separate CRCsare loaded into the shaft processor 4706 wherein one is normal and theother has a STOP command, for example, and parameters like a 0 mmtransection length.

In at least one instance, the primary processor 4702 tracks the statusof the trace element 4734 via a shared universal asynchronousreceiver/transmitter (UART) pin, and the position of the motor 4714 viathe rotary position encoder 4741, for example. The primary processor4702 can be configured to prevent the motor 4714 from running if theprimary processor 4702 detects that the trace element 4734 has beensevered.

In various instances, the primary processor 4702 and/or the safetyprocessor 4704 can be configured to prevent the motor 4714 from runningif a movement of the firing member is detected by the proximal sensor4401′, as described above, after a severed status of the trace element4734 is detected. The detection of the movement of the firing member andthe severed status of the trace element 4734 can be performed by thecartridge detection system 4709, as described above. The shaft processor4706 can be configured to send a STOP command to the primary processor4702 and/or the safety processor 4704 a severed status of the traceelement 4734 is detected. The communication between the shaft processor4706, the primary processor 4702, and/or the safety processor 4704 canbe a CRC communication, for example. In various instances, the safetyprocessor 4704 is configured to watch for the STOP command and to entera sleep mode once the STOP command is received. In various instances,the safety processor 4704 is configured to stop the motor 4714 fromrunning if a computed CRC, which is computed from the received data,does not match the received CRC. A CRC verification module can beemployed by the safety processor 4704 to compute a CRC from the receiveddata and compare the computed CRC with the received CRC.

In various instances, the primary processor 4702, the safety processor4704, and/or the shaft processor 4706 may comprise security codegenerator modules and/or security code verification modules. Securitycodes can be generated by CHECK-SUM, HASH, or other suitable protocols.The security code generation module and/or the security codeverification module may be implemented in hardware, firmware, softwareor any combination thereof. Ensuring the validity of the communicationsbetween the primary processor 4702, the safety processor 4704, and/orthe shaft processor 4706 is important because body fluids may interferewith communicated signals between such processors.

As described above, the shaft processor 4706 can be configured to send aSTOP command to the primary processor 4702 and/or the safety processor4704 via a CRC communication. In one example, the shaft processor 4706includes a security code generator configured to generate a securitycode and attached the security code to the STOP command transmitted tothe primary processor 4702, for example. The primary processor 4702includes a security code verification module configured to verify theintegrity of the transmission received from the shaft processor 4706.The security code verification module is configured to compute asecurity code based on the received STOP command data and compare thecomputed security code to the security code received with the STOPcommand data. If the primary processor 4702 confirms the integrity ofthe received message, the primary processor 4702 may activate a stopmode 4688, for example.

In certain instances, the safety processor 4704 may be tasked withensuring the integrity of messages transmitted to the primary processor4702. In one example, the safety processor 4704 includes a security codeverification module configured to verify the integrity of a messagetransmission from the shaft processor 4706. The security codeverification module of the safety processor 4704 is configured tocompute a security code based on the received STOP command data andcompare the computed security code to the security code received withthe STOP command data. If the safety processor 4704 confirms theintegrity of the received message, the safety processor 4704 mayactivate a stop mode 4688 (FIG. 86), for example.

Turning now to FIG. 83, a circuit 4600 is configured to control apowered surgical instrument, such as the surgical instrument 4500illustrated in FIG. 80. The circuit 4600 is configured to control one ormore operations of the powered surgical instrument 4500. The circuit4600 includes a safety processor 4604 and a main or primary processor4602, which are similar in many respects to the safety processor 4704and the primary processor 4702, respectively. The safety processor 4604and/or the primary processor 4602 are configured to interact with one ormore additional circuit elements to control operation of the poweredsurgical instrument 4500. The primary processor 4602 comprises aplurality of inputs coupled to one or more circuit elements. The circuit4600 can be a segmented circuit. In various instances, the circuit 4600may be implemented by any suitable circuit, such as a printed circuitboard assembly (PCBA) within the powered surgical instrument 4500.

The circuit 4600 comprises a feedback element in the form of a display4609. The display 4609 comprises a display connector coupled to theprimary processor 4602. The display connector couples the primaryprocessor 4602 to a display 4609 through one or more display driverintegrated circuits. The display driver integrated circuits may beintegrated with the display 4609 and/or may be located separately fromthe display 4609. The display 4609 may comprise any suitable display,such as an organic light-emitting diode (OLED) display, a liquid-crystaldisplay (LCD), and/or any other suitable display. In some embodiments,the display 4609 is coupled to the safety processor 4604. Furthermore,the circuit 4600 further comprises one or more user controls 4611, forexample.

The safety processor 4604 is configured to implement a watchdog functionwith respect to one or more operations of the powered surgicalinstrument 4500. In this regard, the safety processor 4604 employs thewatchdog function to detect and recover from malfunctions of the primaryprocessor 4602. During normal operation, the safety processor 4604 isconfigured to monitor for hardware faults or program errors of theprimary processor 4602 and to initiate corrective action or actions. Thecorrective actions may include placing the primary processor 4602 in asafe state and restoring normal system operation.

In at least one aspect, the primary processor 4602 and the safetyprocessor 4604 operate in a redundant mode. The primary processor 4602and the safety processor 4604 are coupled to at least a first sensor.The first sensor measures a first property of the surgical instrument4500. The primary processor 4602 is configured to determine an outputbased on the measured first property of the surgical instrument 4500 andcompare the output to a predetermined value. Likewise, the safetyprocessor 4604 is configured to separately determine an output based onthe measured first property of the surgical instrument 4500 and comparethe output to the same predetermined value. The safety processor 4604and the primary processor 4602 are configured to provide a signalindicative of the value of their determined outputs. When either thesafety processor 4604 or the primary processor 4602 indicates a valueoutside of an acceptable range, appropriate safety measures can beactivated. In certain instances, the primary processor 4602 and thesafety processor 4604 receive their inputs from separate sensors thatare configured to separately measure the first property of the surgicalinstrument 4500. In certain instances, when at least one of the safetyprocessor 4604 and the primary processor 4602 indicates a value withinan acceptable range, the surgical instrument 4500 is allowed to continuein a normal mode of operation. For example, the firing system 4056 canbe allowed to complete a firing stroke of the surgical instrument 4500when at least one of the safety processor 4604 and the primary processor4602 indicates a value within an acceptable range. In such instances, adiscrepancy between the values or results determined by the safetyprocessor 4604 and the primary processor 4602 can be attributed to afaulty sensor or a calculation error, for example.

As illustrated in FIG. 83, linear position encoders 4640 and 4641 arecoupled to the primary processor 4602 and the safety processor 4604,respectively. The position encoder 4640 provides speed and positioninformation about a firing member of the powered surgical instrument4500 to the primary processor 4602 an analog to digital converters 4623a (ADCs). Likewise, the position encoder 4640 provides speed andposition information about a firing member of the powered surgicalinstrument 4500 to the safety processor 4604 through a separate analogto digital converter 4623 b (ADCs). The primary processor 4602 and thesafety processor 4604 are configured to execute an algorithm forcalculating at least one acceleration of the firing member based on theinformation derived from the linear position encoders 4640 and 4641. Theacceleration of the firing member can be determined based on thefollowing equation:

${a = \frac{v_{2} - v_{1}}{t_{2} - t_{1}}},$wherein a is the current acceleration of the firing member, wherein v₂is a current velocity of the firing member recorded at time t₂, andwherein v₁ is a previous velocity of the firing member at a previoustime t₁.

The acceleration of the firing member can also be determined based onthe following equation:

${a = \frac{d_{2} - d_{1}}{\left( {t_{2} - t_{1}} \right)^{2}}},$wherein a is the current acceleration of the firing member, wherein d₂is a distance traveled by the firing member between an initial positionand a current position during a time t₂, and wherein d₁ is a distancetraveled by the firing member between an initial position a previousposition during a time

The primary processor 4602 is further configured to compare thedetermined acceleration value to a predetermined threshold accelerationwhich can be stored in a memory unit in communication with the primaryprocessor 4602, for example. Likewise, the safety processor 4604 isconfigured to compare its determined acceleration value to apredetermined threshold acceleration which can be stored in a memoryunit in communication with the safety processor 4604, for example. Inthe event the primary processor 4602 and/or the safety processor 4604determine that the determined acceleration values are beyond the apredetermined threshold acceleration, appropriate safety measures can betaken such as, for example, stopping power delivery to the motor 4514and/or resetting the firing system 4056. Alternatively, in certaininstances, when at least one of the safety processor 4604 and theprimary processor 4602 indicates an acceptable acceleration value, thesurgical instrument 4500 is allowed to continue in a normal mode ofoperation. For example, the firing system 4056 can be allowed tocomplete a firing stroke of the surgical instrument 4500 when at leastone of the safety processor 4604 and the primary processor 4602 reportsan acceptable acceleration. In such instances, a discrepancy between thevalues or results determined by the safety processor 4604 and theprimary processor 4602 can be attributed to a faulty sensor or acalculation error, for example.

As described above, the primary processor 4602 and the safety processor4604 are further configured to compare the determined accelerationvalues to a predetermined threshold acceleration which can be stored ina memory unit, for example. The threshold acceleration can be determinedfrom a threshold force corresponding to a failure load of a lockoutmechanism of the firing system 4056. In certain instances, the failureload is known to be about 100 lbf. In such instances, Newton's secondlaw of motion can be employed to determine the corresponding thresholdacceleration based on the equation:F=m×a,wherein F is the threshold force, and m is the mass exerting the force.

Acceleration of the firing member of the firing system 4056 can also beassessed by tracking the electrical current drawn by a motor 4514 duringa firing stroke. The load on a firing member driven by the motor 4514through a firing stroke is directly related the electrical current drawnby a motor 4514. Accordingly, the load experienced by the firing membercan be assessed by measuring the electrical current drawn by the motor4514 during a firing stroke. Newton's second law of motion can beemployed to calculate the acceleration of the firing member based on theload experienced by the firing member which can be assessed by trackingthe electrical current drawn by a motor 4514 during the firing stroke.

As illustrated in FIG. 84A, a sensor 4617 can be coupled to a motorcontrol circuit 4619 to measure the current drawn by the motor 4514during the firing stroke. In at least one instance, the sensor 4617 canbe a current sensor or a Hall effect sensor, for example. The readingsof the sensor 4617 can be amplified using a buffer amplifier 4625,digitized using an ADC 4623, and transmitted to the primary processor4602 (FIG. 83) and the safety processor 4604 (FIG. 83) which areconfigured to execute an algorithm to determine the corresponding loadon the firing member and determine an acceleration of the firing memberbased on Newton's second law of motion.

Referring to FIG. 84A, the sensor 4617 can be coupled to the motorcontrol circuit 4619 to measure the current drawn by the motor 4514during the firing stroke. During normal operation of the motor 4514, thereadings of the sensor 4617 are expected to be within a normalpredetermined range. As illustrated in FIG. 84B, the normal range canhave a minimum threshold of about 0.5 A, for example, and a maximumthreshold of about 5.0 A, for example. A sensor reading above themaximum threshold or a sensor reading above zero but below the minimumthreshold can indicate a failure in the sensor 4617. The maximumthreshold can be any value selected from a range of about 4.0 A, forexample, to 6.0 A, for example. The minimum threshold can be any valueselected from a range of about 0.4 A, for example, to 0.6 A, forexample.

As described above, the readings of the sensor 4617 can be amplifiedusing a buffer amplifier 4625, digitized using an ADC 4623, andtransmitted to the primary processor 4602 which is configured to executean algorithm to determine whether the readings of the sensor 4617 arewithin a predetermined normal range. In the event it is determined thatthe readings of the sensor 4617 is beyond the predetermined normalrange, appropriate safety measures can be taken by the primary processor4602. In one example, the primary processor 4602 may permit completionof the firing stroke in a safe mode because the abnormal motor currentreadings are likely due to a faulty sensor 4617. In another example, theprimary processor may cause power delivery to the motor 4514 to bestopped and alert a user to utilize a mechanical bailout feature. Theprimary processor 4602 may alert a user through the display 4058 tocontact a service department to replace the faulty sensor 4617. Theprimary processor 4602 may provide instructions on how to replace thefaulty sensor 4617.

In certain instances, the safety processor 4604 can be configured toreceive readings from another sensor, independent from the sensor 4617,configured to separately measure the current drawn by the motor 4514during the firing stroke. Like the primary processor 4602, the safetyprocessor 4604 can be configured to execute an algorithm to determinewhether the readings of the other sensor are within a predeterminednormal range. If at least one of the primary processor 4602 and thesecondary processor 4604 determines that the current drawn by the motor4514 is within the predetermined normal range, the motor 4514 is allowedto complete the firing stroke. In such instances, a discrepancy betweenthe values or results determined by the safety processor 4604 and theprimary processor 4602 are attributed to a faulty sensor or acalculation error, for example.

In certain instances, the primary processor 4602 and the safetyprocessor 4604 can be configured to track or determine at least oneacceleration of a firing member of the firing system 4056 usingdifferent techniques. If at least one of the primary processor 4602 andthe safety processor 4604 determines that the acceleration of the firingmember is within a normal range, the firing member is allowed tocomplete the firing stroke. A discrepancy between the accelerationvalues determined by the safety processor 4604 and the primary processor4602 can be attributed to a faulty sensor or a calculation error. Thisensures unnecessary interruptions of the firing system 4056 that are dueto a faulty sensor or a calculation error.

In one example, the primary processor 4602 can be configured todetermine or track an acceleration of a firing member of the firingsystem 4056 using a first technique. For example, the primary processor4602 can be configured to determine or track an acceleration of thefiring member by employing the sensor 4617 to measure the current drawnby the motor 4514. The primary processor 4602 can then execute analgorithm for calculating at least one acceleration of the firing memberbased on input from the sensor 4617, as described above. On the otherhand, the safety processor 4604 can be configured to determine or trackthe acceleration of the firing member using a second technique,different than the first technique. For example, the safety processor4604 can be configured to determine or track the same acceleration ofthe firing member by employing the position encoders 4640 to detect theposition of the firing member during a firing stroke. The safetyprocessor 4604 can execute an algorithm for calculating at least oneacceleration of the firing member based on input from the positionencoders 4640, as described above. The calculated accelerations can becompared against a predetermined normal range. In the event, the primaryprocessor 4602 and the safety processor 4604 are in agreement that theirrespective acceleration values are within the normal range, the firingmember is allowed to complete the firing stroke. If, however, theprimary processor 4602 and the safety processor 4604 are in agreementthat their respective acceleration values are outside the normal range,appropriate safety measures can be taken by the primary processor 4602,for example, as described above. In the event of a discrepancy betweenthe outcomes determined by the primary processor 4602 and the safetyprocessor 4604 with regard to the acceleration of the firing member, thefiring member is allowed to complete the firing stroke.

Firing the powered surgical cutting and stapling instrument 4500involves a mechanical component, where a firing trigger is squeezed by auser, and an electrical component, where an electrical current flows tothe motor 4514 in response to a transition of the motor control circuit4515 from an open configuration to a closed configuration when thefiring trigger is squeezed by the user. A trigger-sensing controlcircuit 4627 (FIG. 84A) of the powered surgical cutting and staplinginstrument 4500 includes a firing-trigger Hall effect sensor 4629 whichis configured to detect the transition of the firing trigger 4550between an open configuration and a closed configuration. In addition,the trigger-sensing control circuit 4627 also includes averification-trigger Hall effect sensor 4631 configured to detectcurrent drawn by the motor 4514 when the firing trigger is transitionedto the closed configuration. The sensors 4629 and 4631 are in signalcommunication with the primary processor 4602 and/or the safetyprocessor 4604. The readings of the sensor 4629 and 4631 are amplifiedusing buffer amplifiers 4625, digitized using ADCs 4623 and transmittedto the primary processor 4602 and/or the safety processor 4604 foranalysis and comparison.

During normal operation, the transmitted readings of the sensors 4629and 4631 provide a redundant assurance to the primary processor 4602that the mechanical and electrical components involved in the firing ofthe powered surgical cutting and stapling instrument 4500 arefunctioning properly. In the event of a disagreement, where the sensor4629 indicates that firing trigger has been squeezed while the sensor4631 indicates that no current is being drawn by the motor 4514, theprimary processor 4602 may determine that the sensor 4631 is notfunctioning properly. Where the sensor 4629 fails to indicate thatfiring trigger has been squeezed while the sensor 4631 indicates thatcurrent is being drawn by the motor 4514, the primary processor 4602 maydetermine that the sensor 4629 is not functioning properly. In oneaspect, the primary processor 4602 may permit completion of the firingstroke in a safe mode because the disagreement is attributed to a faultysensor. In another example, the primary processor may cause powerdelivery to the motor 4514 to be stopped and alert a user, for example,to utilize a mechanical bailout feature. The primary processor 4602 mayalert a user through the display 4058 to contact a service department toreplace the faulty sensor. The primary processor 4602 may provideinstructions on how to replace the faulty sensor.

As illustrated in FIG. 83, the primary processor 4602 and/or the safetyprocessor 4604 are in signal communication with one or more linearposition encoders 4640 and/or one or more rotary position encoders 4641.The rotary position encoder 4641 is configured to identify therotational position and/or speed of a motor 4514. In addition, thelinear position encoder 4640 is configured to identify the positionand/or speed of the firing member which is driven by the motor 4514during a firing stroke of the surgical cutting and stapling instrument4500.

During normal operation, the readings of the rotary position encoder4641 are in correlation with the readings of the linear positionencoders 4640. This is because the motor 4514 is operably coupled to thefiring member such that the rotation of the motor 4514 causes the firingmember to be advanced during the firing stroke. The readings of therotary position encoder 4641 may not correlate with the readings of thelinear position encoders 4640 if the advancement speed of the firingmember is outside a tolerance band as measured by the linear positionencoder 4640. Upon detecting a loss in the correlation between thereadings of the rotary position encoder 4641 and the readings of thelinear position encoders 4640, appropriate safety measures can beactivated by the primary processor 4602 and/or the safety processor4604.

In various instances, an input member such as, for example, a sensor orswitch can be positioned in parallel with a first resistive element andin series with a second resistive element to insure that the detectionof failure of the sensor or interruption of its circuit is not merelylack of signal output. Referring to FIG. 85, an electrical circuit 4650includes a beginning-of-stroke switch 4652 positioned in parallel with afirst resistive element 4654 and in series with a second resistiveelement 4656. In addition, the electrical circuit 4650 includes anend-of-stroke switch 4662 positioned in parallel with a first resistiveelement 4664 and in series with a second resistive element 4666.Examples of beginning and end of stroke switches are described in U.S.Pat. No. 8,210,411, entitled MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT,issued on Jul. 3, 2012, which is incorporated herein by reference itsentirety.

The electrical circuit 4650 also includes a voltage source 4660providing an input voltage of 5 volts, for example. As illustrated inFIG. 85, output voltages 4659 and 4669 can be processed by bufferamplifiers 4625 and ADCs 4623 to generate digital outputs which can becommunicated to the primary processor 4602. The primary processor 4602is configured to execute an algorithm to assess one or more statuses ofthe circuit 4650 based on the received digital outputs. In the event theoutput voltage 4659 is equal to the input voltage of the voltage source4660, the primary processor 4602 determines that connection wires 4658are disconnected. In the event the output voltage 4659 is equal to halfof the input voltage of the voltage source 4660, the primary processor4602 determines that connection wires 4658 are connected but thebeginning-of-stroke switch 4652 is in an open configuration. In theevent the output voltage 4659 is equal to one third of the input voltageof the voltage source 4660, the primary processor 4602 determines thatconnection wires 4658 are connected and the beginning-of-stroke switch4652 is in a closed configuration. In the event the output voltage 4659is equal to zero, the primary processor 4602 determines that there is ashort in the circuit 4650. In certain instances, determining that theoutput voltage 4659 is equal to zero indicates a failure of theend-of-stroke switch 4652. In certain instances, determining that theoutput voltage 4659 is equal to the input voltage indicates a failure ofthe end-of-stroke switch 4652.

In the event the output voltage 4669 is equal to the input voltage ofthe voltage source 4660, the primary processor 4602 determines thatconnection wires 4668 are disconnected. In the event the output voltage4669 is equal to half of the input voltage of the voltage source 4660,the primary processor 4602 determines that connection wires 4668 areconnected but the end-of-stroke switch 4662 is in an open configuration.In the event the output voltage 4669 is equal to one third of the inputvoltage of the voltage source 4660, the primary processor 4602determines that connection wires 4668 are connected and theend-of-stroke switch 4662 is in a closed configuration. In the event theoutput voltage 4669 is equal to zero, the primary processor 4602determines that there is a short in the circuit 4650. In certaininstances, determining that the output voltage 4669 is equal to zeroindicates a failure of the end-of-stroke switch 4662. In certaininstances, determining that the output voltage 4669 is equal to theinput voltage indicates a failure of the end-of-stroke switch 4662.

Referring now to FIG. 86, a powered surgical stapling and cuttinginstrument 4500 may comprise a failure response system 4681 thatincludes a number of operational modes that can be selectively engagedin response to input, or the lack thereof, from the above-describedpositions encoders, sensors, and/or switches of the powered surgicalstapling and cutting instrument 4500. As illustrated in FIG. 86, awarning mode 4682 is activated if the readings of the sensor 4617, whichrepresent current drawn by the motor 4514, are beyond a predeterminednormal range. The warning mode 4682 is also activated if a failure of atleast one of the beginning-of-stroke switch 4652 and the end-of-strokeswitch 4662 is detected.

The warning mode 4682 is limited to providing a user of the poweredsurgical cutting and stapling instrument 4500 with a warning withouttaking additional steps to stop or modify the progress or parameters ofa firing stroke. The warning mode 4682 is activated in situations whereaborting a firing stroke is unnecessary. For example, the warning mode4682 is activated when a detected error is deemed to be attributed to afailed sensor or switch. The warning mode 4682 employs the userinterface 4058 to deliver a visual, audio, and/or haptic warning.

The powered surgical cutting and stapling instrument 4500 furtherincludes a warning/back-up system mode 4680. The warning/back-up systemmode 4680 is activated if the readings of the linear position encoder4640 do not correlate with the readings of the rotary position encoder4641. Like the warning mode 4682, the warning/back-up system mode 4680employs the user interface 4058 to deliver a visual, audio, and/orhaptic warning. In addition, warning/back-up system mode 4680 causes aback-up system to be activated. During normal operation, a normal mode4684 employs a primary system that includes primary sensors and primarycontrol means. However, a back-up system which comprises secondarysensors and/or secondary control means is used in lieu of the primarysystem if an error is detected that warrants activation of thewarning/back-up system mode 4680.

Further to the above, the powered surgical cutting and staplinginstrument 4500 also includes a limp mode 4686 which is a failureresponse mode or state that is triggered if (i) the readings of thelinear position encoder 4640 do not correlate with the readings of therotary position encoder 4641 and (ii) a failure of at least one of thebeginning-of-stroke switch 4652 and the end-of-stroke switch 4662 isdetected. Like the warning mode 4682, the limp mode 4686 employs theuser interface 4058 to deliver a visual, audio, and/or haptic warning.In addition, the limp mode 4686 slows the progress of the firing stroke.

In certain instances, the limp mode 4686 can reduce a current rotationalspeed of the motor 4514 by any percentage selected from a range of about75% to about 25%. In one example, the limp mode 4686 can reduce acurrent rotational speed of the motor 4514 by 50%. In one example, thelimp mode 4686 can reduce the current rotational speed of the motor 4514by 75%. The limp mode 4686 may cause a current torque of the motor 4514to be reduced by any percentage selected from a range of about 75% toabout 25%. In one example, the limp mode 4686 may cause a current torqueof the motor 4514 to be reduced by 50%.

Further to the above, the powered surgical cutting and staplinginstrument 4500 also includes a stop mode 4688 which is an escalatedfailure response mode or state that is triggered if (i) the readings ofthe linear position encoder 4640 do not correlate with the readings ofthe rotary position encoder 4641, (ii) a failure of at least one of thebeginning-of-stroke switch 4652 and the end-of-stroke switch 4662 isdetected, and (iii) the readings of the sensor 4617, which representcurrent drawn by the motor 4514, are beyond a predetermined normalrange. Like the warning mode 4682, the stop mode 4688 employs the userinterface 4058 to deliver a visual, audio, and/or haptic warning. Inaddition, when triggered, the stop mode 4688 causes the motor 4514 to bedeactivated or stopped leaving only a mechanical bailout systemavailable for use to retract the firing member to a starting position.The stop mode 4688 employs the user interface 4058 to provide a userwith instructions on operating the bailout system. Examples of suitablebailout systems are described in U.S. Patent Application Publication No.2015/0272569, entitled FEEDBACK ALGORITHMS FOR MANUAL BAILOUT SYSTEMSFOR SURGICAL INSTRUMENTS, filed Mar. 26, 2014, which is incorporatedherein by reference in its entirety.

The above-identified operational modes of the powered surgical staplingand cutting instrument 4500 create redundant electronic control pathwaysthat enable operation of the powered surgical stapling and cuttinginstrument 4500 even as some of the inputs, switches, and/or sensorsfail integrity checks. For example, as illustrated in FIG. 86,triggering the limp mode 4686 requires detecting two separate anddiscrete failures, and triggering the stop mode 4688 requires detectingthree separate and discrete failures. A single failure, however, onlytriggers the warning mode 4682. In other words, the failure responsesystem 4681 of the powered surgical stapling and cutting instrument 4500is configured to escalate to a more secure mode of operation in responseto an escalation in detected failures.

The failure response system 4681 can be implemented using integratedand/or discrete hardware elements, software elements, and/or acombination of both. Examples of integrated hardware elements mayinclude processors, microprocessors, controllers, integrated circuits,application specific integrated circuits (ASIC), programmable logicdevices (PLD), digital signal processors (DSP), field programmable gatearrays (FPGA), logic gates, registers, semiconductor devices, chips,microchips, chip sets, microcontroller, system-on-chip (SoC), and/orsystem-in-package (SIP). Examples of discrete hardware elements mayinclude circuits and/or circuit elements (e.g., logic gates, fieldeffect transistors, bipolar transistors, resistors, capacitors,inductors, relay and so forth). In other embodiments, one or morecontrollers of the present disclosure may include a hybrid circuitcomprising discrete and integrated circuit elements or components on oneor more substrates, for example.

In at least one instance, the failure response system 4681 can beimplemented by a circuit including a controller that comprises one ormore processors (e.g., microprocessor, microcontroller) coupled to atleast one memory circuit. The at least one memory circuit stores machineexecutable instructions that when executed by the processor, cause theprocessor to execute machine instructions to implement one or more ofthe functions performed by the failure response system 4681. Theprocessor may be any one of a number of single or multi-core processorsknown in the art. The memory circuit may comprise volatile andnon-volatile storage media. The processor may include an instructionprocessing unit and an arithmetic unit. The instruction processing unitmay be configured to receive instructions from the one memory circuit.

In at least one aspect, the failure response system 4681 may comprise afinite state machine comprising a combinational logic circuit configuredto implement one or more of the functions performed the failure responsesystem 4681. In one embodiment, a failure response system 4681 maycomprise a finite state machine comprising a sequential logic circuit.The sequential logic circuit may comprise the combinational logiccircuit and at least one memory circuit, for example. The at least onememory circuit can store a current state of the finite state machine.The sequential logic circuit or the combinational logic circuit can beconfigured to implement one or more of the functions performed by one ormore controllers of the present disclosure such as, for example, thecontroller. In certain instances, the sequential logic circuit may besynchronous or asynchronous.

In at least one aspect, as illustrated in FIG. 86, the failure responsesystem 4681 is implemented, at least in part, using a number of logicgates. A logic circuit 4691 can be configured to deliver a binary inputto an AND logic gate 4690 as to whether the readings of the linearposition encoder 4640 correlate with the readings of the rotary positionencoder 4641. The second input of the AND gate 4690 is delivered throughan OR logic gate 4692 which receives inputs from the beginning-of-strokeswitch 4652 and the end-of-stroke switch 4662. The OR logic gate 4692delivers a high output to the AND logic gate 4690 if a failure of atleast one of the beginning-of-stroke switch 4652 and the end-of-strokeswitch 4662 is detected. The AND logic gate 4690 delivers a high output,which causes the limp mode 4686 to be activated, if the logic circuit4691 and the OR logic gate 4692 deliver high outputs to the AND logicgate 4690.

Further to the above, a logic inverter or a NOT logic gate 4694maintains the normal mode 4684 in the absence of a high output from theAND logic gate 4690. An AND gate 4696 is responsible for causing thestop mode 4688 to be activated upon receiving a high output from the ANDlogic gate 4690 and a high output from a high output from a logiccircuit 4698 configured to monitor current drawn by the motor 4514. Thelogic circuit 4698 is configured to receive the readings of the sensor4617, which represent current drawn by the motor 4514, and deliver ahigh output when such readings are beyond a predetermined normal rangewhich indicates a sensor failure. An OR logic gate 4699 is configured tocause the warning mode 4682 to be activated upon receiving a high outputfrom one of the logic circuit 4698 and the OR logic gate 4692.

Referring to FIG. 87, an alternative embodiment of a failure responsesystem 4681′ is depicted. The failure response system 4681′ is similarin many respects to the failure response system 4681 and includes thenormal mode 4684, the limp mode 4686, and the stop mode 4688. Thefailure response system 4681′ includes the AND logic gate 4690, the ORlogic gate 4692, and an AND logic gate 4674. A logic circuit 4670, whichcan be configured to implement a decision block, is configured toreceive an input from the AND logic gate 4690. The logic circuit 4670 isconfigured to activate the limp mode 4686 if the logic circuit 4670receives positive input from the AND logic gate 4690. However, if thelogic circuit 4670 does not receive a positive input from the AND logicgate 4690, the normal mode 4684 remains active.

Further to the above, the failure response system 4681′ includes asecond logic circuit 4672, which can be configured to implement adecision block. The second logic circuit 4672 is configured to receivean input from an AND logic gate 4674. The AND logic gate 4674 delivers apositive output if the limp mode 4686 is active and the logic circuit4698 determines that the readings of the sensor 4617, which representcurrent drawn by the motor 4514, are beyond a predetermined normalrange. If, however, the AND logic gate 4674 does not deliver an outputto the logic circuit 4672, the limp mode 4686 remains active.

Referring to FIG. 88, a failure response system 5001 is similar in manyrespects to the failure response system 4681, and includes the limp mode4686 and the stop mode 4688. The failure response system 5001 isconfigured to transition the powered surgical stapling and cuttinginstrument 4500 from the limp mode 4686 to a stop mode 4688 if (i) thetrigger-sensing control circuit 4627 determines that the readings of thefiring-trigger Hall sensor 4629 and the verification-trigger Hall effectsensor 4631 do not correlate, and (ii)(a) the beginning-stroke-switch4652 is in a closed configuration (FIG. 85) or (ii)(b) the readings ofthe linear position encoder 4640 do not correlate with the readings ofthe rotary position encoder 4641.

As illustrated in FIG. 88, the failure response system 5001 includes anOR logic gate configured to receive a positive input 5008 if thereadings of the linear position encoder 4640 do not correlate with thereadings of the rotary position encoder 4641. The OR logic gate 5004 isalso configured to receive a positive input 5006 from the electricalcircuit 4650 (FIG. 85) if the beginning-stroke-switch 4652 is in aclosed configuration. The failure response system 5001 further includesan AND logic gate 5010 configured to receive a positive input 5012 fromthe trigger-sensing control circuit 4627 if the trigger-sensing controlcircuit 4627 determines that the readings of the firing-trigger Hallsensor 4629 and the verification-trigger Hall effect sensor 4631 do notcorrelate. The OR logic gate 5004 is configured to deliver a positiveinput to the AND logic gate 5010 in response to receiving one of theinputs 5006 and 5008.

The failure response system 5001 further includes a logic circuit 5002,which is configured to implement a decision block. The logic circuit5002 is configured to maintain a limp mode 4686 in the absence of apositive output of the AND logic gate 5010. The logic circuit 5002 isfurther configured to transition from the limp mode 4686 to the stopmode 4688 in the presence of a positive output from the AND logic gate5010.

Referring to FIG. 89, an alternative embodiment of a failure responsesystem 5021 is depicted. The failure response system 5021 is similar inmany respects to the failure response system 4681 and includes thenormal mode 4684 and the stop mode 4688. The failure response system5021 is configured to maintain the powered surgical stapling and cuttinginstrument 4500 in the normal mode 4684 until three separate failuresare detected, as described in greater detail below. Upon detecting suchfailures, the failure response system 5021 causes the stop mode 4688 tobe activated.

Further to the above, the failure response system 5021 includes an ANDlogic gate 5024, an OR logic gate 5026, and an AND logic gate 5028. Alogic circuit 5022, which can be configured to implement a decisionblock, is configured to receive an input from the AND logic gate 5024.The logic circuit 5022 is configured to activate the stop mode 4688 ifthe logic circuit 5022 receives a positive input from the AND logic gate5024. However, if the logic circuit 5024 does not receive a positiveinput from the AND logic gate 5024, the normal mode 4684 remains active.

As illustrated in FIG. 89, the AND logic gate 5024 is coupled to thelogic circuit 4691, which is configured to deliver a binary input to anAND logic gate 5024 as to whether the readings of the linear positionencoder 4640 correlate with the readings of the rotary position encoder4641. The second input of the AND gate 5024 is delivered through the ANDlogic gate 5026 which is which is coupled to the logic circuit 4698. Thelogic circuit 4698 is configured to deliver a binary output to the ANDlogic gate 5026 as to whether the readings of the sensor 4617, whichrepresent current drawn by the motor 4514, are beyond a predeterminednormal range. The second input of the AND gate 5026 is delivered throughan OR logic gate 5028 which receives inputs from the beginning-of-strokeswitch 4652 and the end-of-stroke switch 4662. The OR logic gate 5028delivers a high output to the AND logic gate 4690 if a failure of atleast one of the beginning-of-stroke switch 4652 and the end-of-strokeswitch 4662 is detected.

Accordingly, the failure response system 5021 protects againstmalfunctions that are based on sensor and/or switch errors by requiringa plurality of sensor and/or switch errors to be detected beforeactivating the stop mode 4688. This ensures that a single point failuresuch as a failure of a sensor and/or a switch will not by itself renderthe powered surgical stapling and cutting instrument 4500 inoperable.The failure response system 5021 requires a plurality of inputs toindicate failures prior to activating the stop mode 4688. When onefailure is reported such as, for example, a lack of correlation betweenthe readings of the linear position encoder 4640 the readings of therotary position encoder 4641, the failure response system 5021 isconfigured to look for failures in other related or relevant inputs suchas, for example, motor current inputs, inputs from thebeginning-of-stroke switch 4652 and the end-of-stroke switch 4662,before activating the stop mode 4688.

In at least one instance, a first circuit and a second circuit areconfigured to separately assess or detect an operational parameter of apowered surgical stapling and cutting instrument 4500 such as, forexample, an operational parameter in connection with the performance ofa firing member during a firing stroke of the powered surgical staplingand cutting instrument 4500. In at least one instance, the secondcircuit output can be used to verify and/or as a substitute, within acontrol loop of the firing stroke, for the output of the first circuitshould the output of the first circuit be identified as erroneous.

For example, the primary processor 4702 can be configured to track afirst operational parameter by assessing the current drawn by the motor4514 during the firing stroke, and the safety processor 4704 can beconfigured to track a second operational parameter by assessingcorrelation between the rotational motion of the motor 4514 and thelinear motion of the firing member during the firing stroke. Undernormal operating conditions, the current drawn by the motor 4514corresponds to the speed of the firing member and/or falls within anormal predetermined range. Also, under normal operating conditions, therotational motion of the motor 4514 correlates with the linear motion ofthe firing member. Accordingly, the primary processor 4702 and thesafety processor 4704 separately track separate operational parametersof the powered surgical stapling and cutting instrument 4500 thatprovide feedback as to the performance of the firing member within acontrol loop of the firing stroke.

The primary processor 4702 and/or the safety processor 4704 may beconfigured to generate outputs indicative of whether their respectiveoperational parameters are within normal operating conditions. In oneexample, the output of the safety processor 4704 can be used to verifyand/or as a substitute, within a control loop of the firing stroke, forthe output of the primary processor 4702 should the assessment ofoperational parameter of the safety processor 4704 be identified aserroneous or indicative of abnormal operating conditions while thesecond operational parameter indicates normal operating conditions.

The outputs of the primary processor 4702 and/or the safety processor4704 may comprise activating an operational mode of the powered surgicalstapling and cutting instrument 4500 selected from a group comprising anormal mode, a warning mode, a limp mode, and a stop mode. In oneexample, the output of the primary processor 4702 may compriseactivating a failure response mode such as, for example, a limp mode ora stop mode but if the output of the safety processor 4704 comprisesactivating/continuing a normal mode of operation, the normal mode isused as a substitute for the failure response mode. Accordingly, thepowered surgical stapling and cutting instrument 4500 will continue tooperate in normal mode in spite of the error identified based on theassessment of the operational parameter tracked by the primary processor4702.

In one example, a failure response system can be configured to activatea first failure response mode if a first error is detected, a secondfailure response mode if a second error is detected in addition to thefirst error, and a third failure response mode if a third error isdetected in addition to the first and second errors. In at least oneinstances, a powered surgical stapling and cutting instrument 4500remain operational in the first failure response mode and the secondfailure response mode, and is deactivated in the third failure responsemode.

In one example, a failure response system can be configured to elevateor escalate a failure response to accommodate an escalation in detectedfailures. In one example, a failure response system is configured totransition from a first failure response mode to a second responsefailure response mode in response to an increase in detected errors,wherein the detected errors include at least one sensor failure and/orat least one switch failures. In one example, a failure response systemis configured to activate transition from a first failure response modeto a second failure response mode in response to an increase in detectederrors, wherein the detected errors include at least one measurementoutside a predetermine normal range.

In one example, a failure response system is configured to activate afirst failure response mode if a first error is detected and isconfigured to transition from the first failure response mode to asecond failure response mode if a second error is detected in additionto the first error. In one example, a failure response system isconfigured to activate a first failure response mode if a firstplurality of errors are detected and is configured to transition fromthe first failure response mode to a second failure response mode if asecond plurality of errors are detected, wherein the second plurality oferrors are greater than the first plurality of errors, and wherein thesecond plurality of errors encompasses the first plurality of errors. Inone example, the second failure response mode involves a greater numberof restrictions on operation of the powered surgical stapling andcutting instrument 4500 than the first failure response mode.

EXAMPLES Example 1

A surgical instrument comprising an anvil and an elongate channel,wherein at least one of the anvil and the elongate channel is movable tocapture tissue between the anvil and the elongate channel. The elongatechannel comprises a plurality of first electrical contacts, and aplurality of electrical connectors. The plurality of electricalconnectors further comprise a plurality of second electrical contacts,wherein the electrical connectors are spring-biased such that a gap ismaintained between the first electrical contacts and the secondelectrical contacts. The surgical instrument also comprises a staplecartridge releasably attachable to the elongate channel. The staplecartridge comprises a cartridge body including a plurality of staplecavities and, in addition, a plurality of staples deployable from thestaple cavities into the tissue. The staple cartridge also comprises aplurality of third electrical contacts, wherein the attachment of thestaple cartridge to the elongate channel moves the electrical connectorswhich causes the second electrical contacts to bridge the gap and becomeelectrically coupled to the first electrical contacts.

Example 2

The surgical instrument of Example 1, wherein the staple cartridgecomprises a storage medium configured to store information about thestaple cartridge. The storage medium is accessible by the surgicalinstrument through at least one of the third electrical contacts whenthe cartridge body is attached to the elongate channel.

Example 3

The surgical instrument of Examples 1 or 2, wherein the storage mediumcomprises a memory unit.

Example 4

The surgical instrument of Examples 1, 2, or 3, wherein the informationcomprises an identifier of the staple cartridge.

Example 5

The surgical instrument of Examples 1, 2, 3, or 4, wherein theinformation further comprises a spent status of the staple cartridge.

Example 6

The surgical instrument of Examples 1, 2, 3, 4, or 5, wherein theelectrical connectors are at least partially coated with afluid-repellant coating.

Example 7

The surgical instrument of Examples 1, 2, 3, 4, 5, or 6, wherein thethird electrical contacts are at least partially coated with afluid-repellant coating.

Example 8

The surgical instrument of Examples 5, 6, or 7, wherein the connectorscomprise wearing features configured to at least partially remove thefluid-repellant coating during attachment of the staple cartridge to theelongate channel.

Example 9

The surgical instrument of Example 8, wherein at least one of thewearing features comprises a raised-dome shape.

Example 10

The surgical instrument of Example 1, wherein the staple cartridgecomprises a cartridge-status circuit portion comprising a trace elementconfigured to be broken during deployment of the staples.

Example 11

The surgical instrument of Example 1, wherein the elongate channelcomprises a compressible seal configured to resist fluid ingress betweenthe staple cartridge and the elongate channel when the staple cartridgeis attached to the elongate channel.

Example 12

A staple cartridge for use with an end effector of a surgicalinstrument, wherein the staple cartridge comprises a cartridge bodyreleasably attachable to the end effector, and wherein the cartridgebody comprises a plurality of staple cavities. The staple cartridge alsocomprises a plurality of staples at least partially stored in the staplecavities and, in addition, a camming member movable relative to thecartridge body from a starting position to cause staples to be deployedfrom the staple cavities. The staple cartridge further comprises anelectrical circuit including a plurality of external electrical contactsconfigured to be electrically coupled to corresponding electricalcontacts of the end effector when the cartridge body is attached to theend effector. The electrical circuit also comprises a storage mediumconfigured to store information about the staple cartridge, wherein thestorage medium is accessible through at least one of the externalelectrical contacts when the cartridge body is attached to the endeffector. The electrical circuit further comprises a cartridge-statuscircuit portion including a trace element configured to be broken duringmovement of the camming member.

Example 13

The staple cartridge of Example 12, wherein the storage medium comprisesa memory unit.

Example 14

The staple cartridge of Examples 12 or 13, wherein the informationcomprises an identifier of the staple cartridge.

Example 15

The staple cartridge of Examples 12, 13, or 14, wherein the informationcomprises a spent status of the staple cartridge.

Example 16

The staple cartridge of Example 12, wherein the external electricalconnectors are at least partially coated with a fluid-repellant coating.

Example 17

A staple cartridge for use with an end effector of a surgicalinstrument, wherein the staple cartridge comprises a cartridge bodyreleasably attachable to the end effector, and wherein the cartridgebody comprises a plurality of staple cavities. The staple cartridge alsocomprises a plurality of staples at least partially stored in the staplecavities and, in addition, a sled movable relative to the cartridge bodyfrom a starting position to cause the staples to be deployed from thestaple cavities during a firing stroke. The staple cartridge furthercomprises a detection means for determining a spent status of the staplecartridge and a storage medium configured to store a spent status of thestaple cartridge.

Example 18

The staple cartridge of Example 17, wherein the detection means includesan electrical circuit configured to be transitioned between a closedconfiguration and an open configuration by the sled during a firingstroke.

Example 19

The staple cartridge of Examples 17 or 18, wherein the detection meansincludes a Hall effect sensor.

Example 20

The staple cartridge of Examples 17, 18, or 19, wherein the detectionmeans includes an electrical circuit comprising a conductive bridgeconfigured to be severed during the firing stroke.

Example 21

A powered surgical stapling and cutting instrument, comprising a staplecartridge, wherein the staple cartridge comprises a housing, a pluralityof staple cavities and, in addition, a plurality of staples deployablefrom the staple cavities during a firing stroke. The staple cartridgealso comprises a firing member movable during a firing stroke to deploystaples from the staple cavities and a motor operably coupled to thefiring member, wherein the motor is configured to generate at least onerotational motion to motivate the firing member to cause staples to bedeployed from the staple cavities during a firing stroke. The poweredsurgical stapling and cutting instrument also comprises a failureresponse system comprising a first circuit configured to detect a firstoperational error of the powered surgical stapling and cuttinginstrument if the movement of the firing member and the rotationalmotion of the motor are beyond a predetermined correlation during thefiring stroke. The failure response system also comprises a secondcircuit configured to detect a second operational error of the poweredsurgical stapling and cutting instrument if a failure is detected in atleast one of a beginning-of-stroke switch and an end-of-stroke switch.The failure response system further comprises a control circuitconfigured to activate a first failure response mode if the firstoperational error is detected, wherein the control circuit is configuredto activate a second failure response mode which is different than thefirst failure response mode if the second operational error is detectedin addition to detection of the first operational error.

Example 22

The powered surgical stapling and cutting instrument of Example 21,wherein the first failure response mode is a warning mode.

Example 23

The powered surgical stapling and cutting instrument of Examples 21 or22, wherein the second failure response mode is a limp mode.

Example 24

The powered surgical stapling and cutting instrument of Examples 21, 22,or 23, wherein the motor is run at a reduced speed in the limp mode.

Example 25

The powered surgical stapling and cutting instrument of Examples 21, 22,23 or 24, wherein the firing member is moved at a reduced speed in thelimp mode.

Example 26

The powered surgical stapling and cutting instrument of Example 21,further comprising a third circuit configured to detect a thirdoperational error of the powered surgical stapling and cuttinginstrument if a current drawn by the motor during a firing stroke isbeyond a predetermined range.

Example 27

The powered surgical stapling and cutting instrument of Example 26,wherein the control circuit is configured to activate a third failureresponse mode which is different than the first failure response modeand the second failure response mode if the third operational error isdetected in addition to detection of the first operational error and thesecond operational error.

Example 28

The powered surgical stapling and cutting instrument of Example 27,wherein the third failure response mode is more restrictive than thesecond failure response mode.

Example 29

A powered surgical stapling and cutting instrument, comprising a staplecartridge wherein the staple cartridge comprises a housing, a pluralityof staple cavities and, in addition, a plurality of staples deployablefrom the staple cavities during a firing stroke. The staple cartridgealso comprises a firing member movable during a firing stroke to causestaples to be deployed from the staple cavities, and a motor operablycoupled to the firing member, wherein the motor is configured togenerate at least one rotational motion to motivate the firing member tocause staples to be deployed from the staple cavities during a firingstroke. The powered surgical stapling and cutting instrument furthercomprises a failure response system which comprises a first circuitconfigured to detect a first operational error of the powered surgicalstapling and cutting instrument if movement of the firing member and therotational motion of the motor are beyond a predetermined correlationduring a firing stroke. The failure response system also comprises asecond circuit configured to detect a second operational error of thepowered surgical stapling and cutting instrument if a failure isdetected in at least one of a beginning-of-stroke switch and anend-of-stroke switch. The failure response system further comprises acontroller which includes a memory and a storage medium comprisingprogram instructions which, when executed by the processor, cause theprocessor to activate a first failure response mode if the firstoperational error is detected, and also cause the processor to activatea second failure response mode which is different than the first failureresponse mode if the second operational error is detected in addition todetection of the first operational error. Example 30—The poweredsurgical stapling and cutting instrument of Example 29, wherein thefirst failure response mode is a warning mode.

Example 31

The powered surgical stapling and cutting instrument of Examples 29 or30, wherein the second failure response mode is a limp mode.

Example 32

The powered surgical stapling and cutting instrument of Examples 29, 30,or 31, wherein the motor is run at a reduced speed in the limp mode.

Example 33

The powered surgical stapling and cutting instrument of Examples 29, 30,31, or 32, wherein the firing member is moved at a reduced speed in thelimp mode.

Example 34

The powered surgical stapling and cutting instrument of Example 29,further comprising a third circuit configured to detect a thirdoperational error of the powered surgical stapling and cuttinginstrument if a current drawn by the motor during a firing stroke isbeyond a predetermined range.

Example 35

The powered surgical stapling and cutting instrument of Example 29,wherein the storage medium comprises program instructions which, whenexecuted by the processor, cause the processor to activate a thirdfailure response mode which is different than the first failure responsemode and the second failure response mode if the third operational erroris detected in addition to detection of the first operational error andthe second operational error.

Example 36

The powered surgical stapling and cutting instrument of Example 35,wherein the third failure response mode is more restrictive than thesecond failure response mode.

Example 37

A failure response system for use with a powered surgical stapling andcutting instrument configured to deploy a plurality of staples intotissue during a firing stroke, wherein the failure response systemcomprises a first circuit configured to detect a first operational errorof the powered surgical stapling and cutting instrument during a firingstroke, and a second circuit configured to detect a second operationalerror of the powered surgical stapling and cutting instrument during afiring stroke, wherein the second operational error is different thanthe first operational error. The failure response system also comprisesa third circuit configured to detect a third operational error of thepowered surgical stapling and cutting instrument during a firing stroke,wherein the third operational error is different than the firstoperational error and the second operational error. The failure responsesystem further comprises a control circuit configured to activate afirst failure response mode if the first operational error is detected,wherein the control circuit is configured to activate a second failureresponse mode, which is different than the first failure response modeif the second operational error is detected in addition to detection ofthe first operational error. The control circuit is configured toactivate a third failure response mode which is different than the firstfailure response mode and the second failure response mode if the thirdoperational error is detected in addition to detection of the firstoperational error and the second operational error.

Example 38

The failure response system of Example 37, wherein the first failureresponse mode is a warning mode.

Example 39

The failure response system of Examples 37 or 38, wherein the secondfailure response mode is a limp mode.

Example 40

The failure response system of Examples 37, 38, or 39, wherein the thirdfailure response mode is more restrictive than the second failureresponse mode.

Example 41

A powered surgical stapling and cutting instrument comprising, a staplecartridge comprising a housing, a plurality of staple cavities, and, inaddition, a plurality of staples deployable from the staple cavitiesduring a firing stroke. The staple cartridge also comprises a firingmember movable during a firing stroke to cause staples to be deployedfrom the staple cavities, and a motor operably coupled to the firingmember. The motor is configured to generate at least one rotationalmotion to motivate the firing member to cause the staples to be deployedfrom the staple cavities during the firing stroke. The powered surgicalstapling and cutting instrument also comprises a primary controllercomprising a primary processor and a primary storage medium storingfirst program instructions which, when executed by the primaryprocessor, cause the primary processor to determine a first accelerationof the firing member during a firing stroke and compare the firstacceleration to a predetermined threshold acceleration. The poweredsurgical stapling and cutting instrument further comprises a secondarycontroller including a secondary processor and a secondary storagemedium storing second program instructions which, when executed by thesecondary processor, cause the secondary processor to determine a secondacceleration of the firing member during a firing stroke and to comparethe second acceleration to the predetermined threshold value.

Example 42

The powered surgical stapling and cutting instrument of Example 41,wherein the first acceleration is determined based on a distance betweena first position and a second position, wherein the distance is traveledby the firing member during a firing stroke.

Example 43

The powered surgical stapling and cutting instrument of Examples 41 or42, further comprising a sensor configured to detect the firing memberat the second position.

Example 44

The powered surgical stapling and cutting instrument of Example 43,wherein the sensor is a linear position encoder.

Example 45

The powered surgical stapling and cutting instrument of Examples 43 or44, wherein the sensor is in electrical communication with the primaryprocessor.

Example 46

The powered surgical stapling and cutting instrument of Examples 41, 42,43, 44, or 45, wherein the second acceleration is separately determinedby the secondary processor based on the distance.

Example 47

The powered surgical stapling and cutting instrument of Examples 41, 42,43, 44, 45, or 46, further comprising another sensor configured todetect the firing member at the second position.

Example 48

The powered surgical stapling and cutting instrument of Example 47,wherein the other sensor is a linear position encoder.

Example 49

The powered surgical stapling and cutting instrument of Examples 47 or48, wherein the other sensor is in electrical communication with thesecondary processor.

Example 50

The powered surgical stapling and cutting instrument of Examples 41, 42,43, 44, 45, 46, 47, 48, or 49, wherein the primary processor isconfigured to activate a failure response mode if (i) the firstacceleration is beyond the predetermined threshold value and (ii) thesecond acceleration is beyond the predetermined threshold value.

Example 51

The powered surgical stapling and cutting instrument of Examples 41, 42,43, 44, 45, 46, 47, 48, 49, or 50, wherein the failure response modecomprises stopping the motor.

Example 52

The powered surgical stapling and cutting instrument of Examples 41, 42,43, 44, 45, 46, 47, or 48, wherein the primary processor is configuredto activate a failure response mode if at least one of the firstacceleration and the second acceleration is beyond the predeterminedthreshold value.

Example 53

The powered surgical stapling and cutting instrument of Example 52,wherein the failure response mode comprises stopping the motor.

Example 54

The powered surgical stapling and cutting instrument of Example 41,wherein the second program instructions further cause the secondaryprocessor to generate an output based on the comparison of the secondacceleration to the predetermined threshold value and cause the outputto be communicated to the primary controller.

Example 55

A powered surgical stapling and cutting instrument comprising a staplecartridge comprising a housing, a plurality of staple cavities, and inaddition, a plurality of staples deployable from the staple cavitiesduring a firing stroke. The powered surgical stapling and cuttinginstrument also comprises a firing member movable during a firing stroketo cause the staples to be deployed from the staple cavities, and amotor operably coupled to the firing member. The motor is configured togenerate at least one rotational motion to motivate the firing member todeploy staples from the staple cavities during a firing stroke. Thepowered surgical stapling and cutting instrument further comprises aprimary circuit including a primary processor configured to assess afirst operational parameter indicative of performance of the firingmember during a firing stroke and generate a first output based on theassessment of the first operational parameter. The powered surgicalstapling and cutting instrument further comprises a second circuitincluding a safety processor configured to assess a second operationalparameter indicative of the performance of the firing member during afiring stroke, wherein the second operational parameter is differentthan the first operational parameter and to generate a second outputbased on the assessment of the second operational parameter, wherein thesecond output is used to verify the first output within a control loopof a firing stroke.

Example 56

The powered surgical stapling and cutting instrument of Example 55,wherein the second output is used as a substitute for the first outputif it is determined that the first operational parameter indicates anabnormal performance of the firing member during a firing stroke whilethe second operational parameter indicates a normal performance of thefiring member.

Example 57

The powered surgical stapling and cutting instrument of Example 55,wherein the first output is configured to activate a mode of operationselected from a group comprising a normal mode, a warning mode, a limpmode, and a stop mode.

Example 58

The powered surgical stapling and cutting instrument of Examples 55 or57, wherein the second output is configured to activate a mode ofoperation selected from a group comprising a normal mode, a warningmode, a limp mode, and a stop mode.

Example 59

The powered surgical stapling and cutting instrument of Example 55,wherein the first output is communicated to the safety processor in amessage comprising the first output and a security code.

Example 60

The powered surgical stapling and cutting instrument of Example 59,wherein the security code comprises a cyclic redundancy check (CRC).

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The entire disclosures of:

U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC DEVICE,which issued on Apr. 4, 1995;

U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT HAVINGSEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on Feb. 21,2006;

U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING ANDFASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which issued onSep. 9, 2008;

U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL INSTRUMENTWITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS, which issued on Dec.16, 2008;

U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING ANARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;

U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS, whichissued on Jul. 13, 2010;

U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE IMPLANTABLEFASTENER CARTRIDGE, which issued on Mar. 12, 2013;

U.S. patent application Ser. No. 11/343,803, entitled SURGICALINSTRUMENT HAVING RECORDING CAPABILITIES; now U.S. Pat. No. 7,845,537;

U.S. patent application Ser. No. 12/031,573, entitled SURGICAL CUTTINGAND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed Feb. 14, 2008;

U.S. patent application Ser. No. 12/031,873, entitled END EFFECTORS FORA SURGICAL CUTTING AND STAPLING INSTRUMENT, filed Feb. 15, 2008, nowU.S. Pat. No. 7,980,443;

U.S. patent application Ser. No. 12/235,782, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT, now U.S. Pat. No. 8,210,411;

U.S. patent application Ser. No. 12/249,117, entitled POWERED SURGICALCUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM,now U.S. Pat. No. 8,608,045;

U.S. patent application Ser. No. 12/647,100, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROLASSEMBLY, filed Dec. 24, 2009; now U.S. Pat. No. 8,220,688;

U.S. patent application Ser. No. 12/893,461, entitled STAPLE CARTRIDGE,filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;

U.S. patent application Ser. No. 13/036,647, entitled SURGICAL STAPLINGINSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No. 8,561,870;

U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat.No. 9,072,535;

U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15, 2012;now U.S. Pat. No. 9,101,358;

U.S. patent application Ser. No. 13/800,025, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. Pat.No. 9,345,481;

U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. PatentApplication Publication No. 2014/0263552;

U.S. Patent Application Publication No. 2007/0175955, entitled SURGICALCUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM,filed Jan. 31, 2006; and

U.S. Patent Application Publication No. 2010/0264194, entitled SURGICALSTAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, filed Apr. 22,2010, now U.S. Pat. No. 8,308,040, are hereby incorporated by referenceherein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdo not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A powered surgical stapling and cuttinginstrument, comprising: a staple cartridge, comprising: a housing; aplurality of staple cavities; a plurality of staples deployable fromsaid staple cavities during a firing stroke; a firing member movableduring said firing stroke to cause said staples to be deployed from saidstaple cavities; and a motor operably coupled to said firing member,wherein said motor is configured to generate at least one rotationalmotion to motivate said firing member to cause said staples to bedeployed from said staple cavities during said firing stroke; a primarycontroller, comprising: a primary processor; and a primary storagemedium storing first program instructions which, when executed by theprimary processor, cause the primary processor to: determine a firstacceleration of said firing member during said firing stroke; andcompare said first acceleration to a predetermined thresholdacceleration; and a secondary controller, comprising: a secondaryprocessor; and a secondary storage medium storing second programinstructions which, when executed by said secondary processor, cause thesecondary processor to: determine a second acceleration of said firingmember during said firing stroke; and compare said second accelerationto said predetermined threshold value.
 2. The powered surgical staplingand cutting instrument of claim 1, wherein said first acceleration isdetermined based on a distance between a first position and a secondposition, wherein said distance is traveled by said firing member duringsaid firing stroke.
 3. The powered surgical stapling and cuttinginstrument of claim 2, further comprising a sensor configured to detectsaid firing member at said second position.
 4. The powered surgicalstapling and cutting instrument of claim 3, wherein said sensor is alinear position encoder.
 5. The powered surgical stapling and cuttinginstrument of claim 3, wherein said sensor is in electricalcommunication with said primary processor.
 6. The powered surgicalstapling and cutting instrument of claim 5, wherein said secondacceleration is separately determined by said secondary processor basedon said distance.
 7. The powered surgical stapling and cuttinginstrument of claim 6, further comprising another sensor configured todetect said firing member at said second position.
 8. The poweredsurgical stapling and cutting instrument of claim 7, wherein said othersensor is a linear position encoder.
 9. The powered surgical staplingand cutting instrument of claim 7, wherein said other sensor is inelectrical communication with said secondary processor.
 10. The poweredsurgical stapling and cutting instrument of claim 9, wherein saidprimary processor is configured to activate a failure response mode if(i) said first acceleration is beyond said predetermined threshold valueand (ii) said second acceleration is beyond said predetermined thresholdvalue.
 11. The powered surgical stapling and cutting instrument of claim10, wherein said failure response mode comprises stopping said motor.12. The powered surgical stapling and cutting instrument of claim 9,wherein said primary processor is configured to activate a failureresponse mode if at least one of said first acceleration and said secondacceleration is beyond said predetermined threshold value.
 13. Thepowered surgical stapling and cutting instrument of claim 12, whereinsaid failure response mode comprises stopping said motor.
 14. Thepowered surgical stapling and cutting instrument of claim 1, whereinsaid second program instructions further cause the secondary processorto: generate an output based on said comparison of said secondacceleration to said predetermined threshold value; and cause saidoutput to be communicated to said primary controller.
 15. A poweredsurgical stapling and cutting instrument, comprising: a staplecartridge, comprising: a housing; a plurality of staple cavities; and aplurality of staples deployable from said staple cavities during afiring stroke; a firing member movable during said firing stroke tocause said staples to be deployed from said staple cavities; a motoroperably coupled to said firing member, wherein said motor is configuredto generate at least one rotational motion to motivate said firingmember to deploy said staples from said staple cavities during saidfiring stroke; a primary circuit, comprising a primary processorconfigured to: assess a first operational parameter indicative ofperformance of said firing member during said firing stroke; andgenerate a first output based on an assessment of said first operationalparameter; and a second circuit, comprising a safety processorconfigured to: assess a second operational parameter indicative of saidperformance of said firing member during said firing stroke, whereinsaid second operational parameter is different than said firstoperational parameter; and generate a second output based on anassessment of said second operational parameter, wherein said secondoutput is used to verify said first output within a control loop of saidfiring stroke.
 16. The powered surgical stapling and cutting instrumentof claim 15, wherein said second output is used as a substitute for saidfirst output if it is determined that said first operational parameterindicates an abnormal performance of said firing member during saidfiring stroke while said second operational parameter indicates a normalperformance of said firing member.
 17. The powered surgical stapling andcutting instrument of claim 15, wherein said first output is configuredto activate a mode of operation selected from a group comprising anormal mode, a warning mode, a limp mode, and a stop mode.
 18. Thepowered surgical stapling and cutting instrument of claim 15, whereinsaid second output is configured to activate a mode of operationselected from a group comprising a normal mode, a warning mode, a limpmode, and a stop mode.
 19. The powered surgical stapling and cuttinginstrument of claim 15, wherein said first output is communicated tosaid safety processor in a message comprising said first output and asecurity code.
 20. The powered surgical stapling and cutting instrumentof claim 19, wherein said security code comprises a cyclic redundancycheck (CRC).